Cursor 87 Ent m38.10

C87 ENT M38.
10
C87 ENT M62.10
TECHNICAL AND
REPAIR MANUAL
OCTOBER 2010 EDITION
C87 ENT M38.10
1.2 C87 ENT M62.10 OCTOBER 2010
FOREWORD
We strongly recommend that you carefully read the
indications contained in this document: compliance with
these indications protects the engine from irregular
operation, assures reliability, safeguards sea-going and
protects maintenance personnel from accident hazards.
The indications contained in this document pertain to the
C87 ENT M38.10 - C87 ENT M62.10 marine engines and
complement the FPT Marine Diesel Engines Installation
Handbook. You should refer to this for anything that is not
explained herein.
Technical engineers and fitters must comply with work safety
regulations. They must implement and adopt the methods
foreseen for personal safety while carrying out maintenance
or checks.
There is a reminder of the regulations for engine handling at
the end of Section 6 of the present publication.
To start the engine, you must adhere to the procedure stated
at the end of Section 5 of the present publication.
To get best engine performance you must conform with its
intended mission profile.The engine must not be used for
purposes other than those stated by the manufacturer.
FPT is available for a prior examination of any requirements
regarding special installations, should this be necessary.
In particular
- Use of unsuitable fuels and oils may compromise the
engine's regular operation, reducing its performance,
reliability and working life.
- Exclusive use of FPT Original Parts is a necessary
condition to maintain the engine in its original integrity.
- Any tampering, modifications, or use of non-original
parts may jeopardize the safety of service personnel and
boat users.
To obtain spare parts, you must indicate:
- Commercial code, serial number and the indications
shown on the engine tag;
- The number of the spare part. This can be found in the
spare part catalog.
The information provided below refers to engine
characteristics current at the date of publication.
FPT reserves the right to make modifications at any time and
without advance notice, to meet technical or commercial
requirements or to comply with local legal and regulatory
requirements.
We refuse all liability

for any errors and omissions.
The reader is reminded that the FPT Technical Assistance
Network is always at the Customer's side with its
competence and professionalism.
Publication edited by:
FPT - Fiat Powertrain Technologies
www.fptpowertrain.com
Printed P3D32C005 E - 2nd Ed. 10.10
C87 ENT M38.10
OCTOBER 2010 C87 ENT M62.10 1.3
SECTION CONTENTS
Section Page
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . 35
3. ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . 43
4. DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 61
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 77
6. SERVICING OPERATIONS
ON INSTALLED ENGINE . . . . . . . . . . . . . . . 83
7. TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8. OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9. SAFETY REGULATIONS . . . . . . . . . . . . . . . . 183

C87 ENT M38.10
1.4 C87 ENT M62.10 OCTOBER 2010
PAGE LEFT INTENTIONALLY BLANK

C87 ENT M38.10
OCTOBER 2010 OVERVIEW C87 ENT M62.10 1.5
SECTION 1
OVERVIEW
Page
IDENTIFICATION DATA . . . . . . . . . . . . . . . . 7
COMMERCIAL CODE . . . . . . . . . . . . . . . . . 8
PRODUCT MODEL NUMBER . . . . . . . . . . . 9
COMBUSTION AIR INTAKE AND EXHAUST

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Comburent air filter . . . . . . . . . . . . . . . . . . . . . 11
Turbocompressor . . . . . . . . . . . . . . . . . . . . . . 11
Air/sea-water heat exchanger . . . . . . . . . . . . . 11
COOLING FRESH WATER CLOSED LOOP 12
Tube bundle water/water heat exchanger . . . 13
Bypass junction for thermostatic valve . . . . . . 13
SEAWATER OPEN COOLING LOOP . . . . . 14
Sea water pump . . . . . . . . . . . . . . . . . . . . . . . 15
ENGINE OIL - LUBRICATION LOOP . . . . . . 16
Oil fume recycle (Blow-by) . . . . . . . . . . . . . . . 17
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL SUPPLY DIAGRAM . . . . . . . . . . . . . . . . 19
Pump assembly . . . . . . . . . . . . . . . . . . . . . . . . 20
Low pressure feed pump . . . . . . . . . . . . . . . . . 21
Pressure control solenoid valve . . . . . . . . . . . . 23
Low pressure limiter valve . . . . . . . . . . . . . . . . 23
High pressure pump . . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
RAIL (PRESSURE ACCUMULATOR) . . . . . . . 26
Electroinjector . . . . . . . . . . . . . . . . . . . . . . . . . 26
C87 ENT M38.10
1.6 C87 ENT M62.10 OVERVIEW OCTOBER 2010
Page
EDC 7 Electronic Central Unit . . . . . . . . . . . . 27
Air pressure/temperature sensor . . . . . . . . . . 27
Atmospheric pressure sensor . . . . . . . . . . . . . 27
Oil pressure/temperature sensor . . . . . . . . . . 28
Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . 28
Camshaft sensor . . . . . . . . . . . . . . . . . . . . . . . 29
Coolant temperature sensor . . . . . . . . . . . . . . 29
Fuel temperature sensor . . . . . . . . . . . . . . . . . 30
Throttle lever position . . . . . . . . . . . . . . . . . . 30
Fuel pressure sensor on rail . . . . . . . . . . . . . . 30
SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . . . . . 31
Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Metering and fuel injection . . . . . . . . . . . . . . . 31
Injection advance management . . . . . . . . . . . . 31
Pre-injection . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Injection pressure modulation . . . . . . . . . . . . . 32
Idling adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 32
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EDC indicator light . . . . . . . . . . . . . . . . . . . . . 32
Fuel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Linearization of the acceleration gradient . . . . 32
Balance of the cylinder torque delivery . . . . . . 32
Rotation speed control . . . . . . . . . . . . . . . . . . 32
Top speed limitation . . . . . . . . . . . . . . . . . . . . 32
Cut off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
C87 ENT M38.10
IDENTIFICATION DATA
Figure 1
04_002_N
1. Trade name/version - 2. Homologation - 3. Production serial number- 4. Maximum rated power -

5. Family of engines - 6. Trade name - 7. Design number- 8. Programming code - 9. Year of production -
10. Homologation number.
Figure 2
143677
The engine identification data are stenciled on a tag positioned over the engine coolant tank
C87 ENT M38.10
COMMERCIAL CODE
The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for technical purposes
and to identify the engine's components, this is the purpose of the ENGINE S/N.
C 87 E N T M 38 . 1 0
62
VERSION
VERSION:
TURBOCOMPRESSOR:
1 = COOLED
2 = NOT COOLED
MAXIMUM PERFORMANCE LEVEL ACHIEVABLE

38 = 380 CV
62 = 620 CV
APPLICATION: M = MARINE
AIR INTAKE: T = INTERCOOLED SUPERCHARGED
BLOCK: N = NON STRUCTURAL
FUEL SUPPLY: E = ELECTRONIC INJECTION
DISPLACEMENT: 8.710 c.c.
ENGINE FAMILY IDENTIFIER: C = CURSOR

C87 ENT M38.10
PRODUCT MODEL NUMBER
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize
its application and power output level. It is stamped on the side of the crank-case.
F 2 C E 0 6 8 6 A * A 0 0 1
VARIANTS TO
BASIC ENGINE
ACTUAL POWER OUTPUT
POWER RANGE
INTENDED USE (6 = MARINE)
FUEL + INJECTION (8 = DIESEL, TCA, DIRECT INJECTION)
NO. OF CYLINDERS
NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL)
ENGINE
DESIGN ITERATION
ENGINE FAMILY IDENTIFIER

C87 ENT M38.10
COMBUSTION AIR INTAKE AND EXHAUST SYSTEM

Figure 3
143694
Intake Exhaust Sea water
Description and Operation Exhaust gas expelled by the engine flows through the cooled
Air, drawn in and compressed by the turbocompressors, exhaust manifold to reach the turbocompressors rotors.
flows through the heat exchanger together with sea water. Exhaust manifold and turbocompressor body are cooled by
The latter, by reducing temperature, allows an increase in the the fresh water loop. Exhaust gases flow into the exhaust
engine's volumetric efficiency. terminal and, when provided, they are mixed with the sea
The air density at the inlet of the intake manifold is measured water it carries for overboard discharge.
by two sensors, for pressure and temperature, allowing the
ECU of the EDC system to calculate fuel dosage relative to
the actual quantity of air available for combustion.
Lubricating oil vapors (blow-by) not condensed in the
separator, are sent to the engine intake by a gauged hole
downstream of the air filters.
C87 ENT M38.10
Comburent air filter Air/sea-water heat exchanger
Figure 4 Figure 6
134384
1. Filter clogging sensor.
Turbocompressor
Figure 5
143670
1. Sea-water outlet - 2. Sacrificial anode (Zinc) -

3. Sea-water inlet - 4. comburent air inlet -
5. Comburent air outlet
The flow of water coming from the sea-water pump goes
through the tube bundle (3) and, by going through it, absorbs
some of the heat of the overheated air of the
turbosupercharge, passing through the exchanger coming
from the turbocompressor (4).
The outlet water (1) is conveyed towards the fresh
water/sea-water heat exchanger, while the
1. Coolant inlet.
turbosupercharged air, cooled down, reaches the induction
The engine is turbosupercharged by a fixed geometry turbine manifold (5) and from there reaches the cylinders.
with no waste-gate control.
The turbine is cooled by the coolant circulation from the
crankcase.
The compressor-turbine spindle rotates on brass bearings
lubricated by pressure lubrication, directly from the oil filter.
C87 ENT M38.10
COOLING FRESH WATER CLOSED LOOP

Figure 7
High temperature liquid

Low temperature liquid
Low temperature liquid
Sea water
143697
Description and operation

The centrifuge pump, rotated by the drive shaft with a poly-V From the bypass fitting the liquid is then injected into the heat
belt, draws in the coolant coming from the fresh water/sea exchange chamber of the exhaust manifold - through which
water heat exchanger or from the exhaust manifold cooling it flows going to touch the body of the waste gate, of a
loop and sends it into the block, where it comes in contact portion the exhaust and of the turbo compressor. When it
with the lubricating oil heat exchanger. It then touches the returns into the bypass junction it comes in contact with the
heat exchange areas of the cylinders and subsequently those wax actuator of the thermostatic valve. This will throttle
of the engine head, from which it exits flowing through the flows according to temperature.
junction fitting that contains the temperature sensors for the Part of the liquid will enter the tank and flow through the tube
instrument panel and the injection system. This junction has bundle heat exchanger, releasing heat to sea water, while the
the purpose of bypassing the coolant from the engine head rest will go directly to the pump, to be recirculated.
to the exhaust manifold and from the exhaust manifold to the
thermostat - which routes it according to the temperature
either to the water/water heat exchanger or to the
recirculation pump.
C87 ENT M38.10
Tube bundle water/water heat exchanger

Figure 8
143671
1. Sea water outlet to overboard discharge - 2. Sea water inlet from after cooler - 3. Coolant inlet from thermostatic valve -
4. Coolant outlet to pump.
Bypass junction for thermostatic valve
Figure 9
05_066_C
1. Bypass flow to engine - 2. Outflow from engine - 3. Outflow from exhaust manifold - 4. Inflow to exhaust manifold -
5. Flow to sea water heat exchanger - 6. Temperature sensor.
C87 ENT M38.10
SEA WATER OPEN COOLING LOOP

Figure 10
143698
Sea water
Description and operation The configuration of the discharge lines depends on the
choice of a dry chimney exhaust, or a mixed one. The
Sea water, drawn from under the keel and necessarily filtered,
outlet pipe will carry the water directly to the overboard
is drawn by the pump and sent to the supercharger air heat
discharge or, if the water/exhaust gas mixer solution is
exchanger and from there to the water/water heat
exchanger of the closed cooling loop; only after this will it adopted, a conduit will connect the outlet of the last heat
flow through the heat exchanger for the gearbox oil, if one exchanger with the mixer inflow junction pipe.
is provided.
C87 ENT M38.10
Sea water pump
Figure 11
139550
1. Pump impeller seat - 2. Driving gear shaft -

3. Sea water intake - 4. Sea water delivery.
The sea water pump, centrifugal type, is rotated by the gears
keyed to the rear of the flywheel.
C87 ENT M38.10
ENGINE OIL - LUBRICATION LOOP
Figure 12
Sump return oil 143695
Delivery oil
Description and operation The blow-by vapor condenser, provided with filter and safety
The gear pump, rotated by the gears at the rear of the valve, is located on the upper part of the timing mechanism
flywheel sends the lubricating oil directly to the heat lid. The vapors, after returning to the liquid state, will flow
exchanger which, incorporated in the block and lapped by from the vapor condensor into the sump. The engine is
the coolant, reduces temperature to maintain optimal provided with the pre-lubrication system on request. This can
lubricating capability. inject enough oil into the engine's ducts to guarantee a totally
The thermostatic valve that regulates oil flow is located at the safe start.
inlet of the heat exchanger, opening the bypass pipe if The operation of the electrical pre-lubrication pump (on
temperature falls below calibration temperature. request), is automatically controlled by the ECU electronic
From the output of the heat exchanger, the oil is sent to the unit.
filter assembly and from this back to the engine block to This system, with the aid of the flow-switching solenoid valve,
lubricate all anti-friction elements. also permits the oil sump to be emptied and filled.
Detailed descriptions of this operation are provided in
Section 3.
C87 ENT M38.10
SUPPLY
The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless
from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.
Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.
When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the
rail takes place.
Figure 14
149570
High pressure
Low pressure
C87 ENT M38.10
SUPPLY
The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless
from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.
Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.
When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the
rail takes place.
Figure 14
149570
High pressure
Low pressure
C87 ENT M38.10
FUEL SUPPLY DIAGRAM

Figure 15
High pressure
Low pressure
127140
1. High-pressure pump - 2. Fuel filter - 3.Tank - 4. Fuel pre-filter - 5.ECU - 6. Electric injectors - 7.Common Rail -
8. Pressure sensor
CAUTION
After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level.
(IT MUST NOT INCREASE).
C87 ENT M38.10
Pump assembly
Figure 16
1. Connector fuel outlet to rail - 2. High pressure pump - 3. Pressure control solenoid - 4. Fuel inlet connector from filter -
5. Fuel outlet connector to recirculation manifold - 6. Fuel inlet from tank - 7. Fuel outlet connector from low pressure
pump to filter - 8. Low pressure pump.
The high pressure pump is made up of three radial pumping

elements driven by a tappet set into rotation by a gear of the
timing shaft. In the rear part the feed mechanical pump, driven
by the radial pump, is fitted.
The pressure control solenoid valve is located on its side.
The positioning of the pump does not require timing as the
injections management is entirely electronically controlled.
C87 ENT M38.10
Low pressure feed pump

Figure 17
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
The gear wheel pump is assembled on the rear part of the It is set into rotation by the high pressure pump shaft. Under
high pressure pump. It transfers the fuel from the tank to the normal operation conditions, the fuel flow inside the mech
high pressure pump. anical pump is illustrated in Figure 17.
Figure 18
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
In the case of overpressure at the outlet, Figure 18, the recir (2), recirculating the fuel in excess inside the pump and
culation valve comes into action. keeping a pressure rating equal to that of the setting of the
The existing pressure, overcoming the spring valve elastic valve.
strength (1), connects the outlet with the inlet through a duct
C87 ENT M38.10
Figure 19
A. Fuel inlet from tank - B. Fuel oulet to filter - 1. Recirculation valve - 2. By-pass valve.
Figure 19 represents the section of the pump during the stage

of filling up the line, as an example by means of the manual
pump located on the pre-filter. With the engine not in
rotation, due to the pressure in the inlet, the by-pass valve (2)
opens up enabling the fuel to flow towards the filter.
C87 ENT M38.10
Pressure control solenoid valve Low pressure limiter valve
Figure 20 Figure 21
Assembled in parallel to the pressure control solenoid valve,

has the function of keeping the inlet pressure constant to the
value of 5 bar, that is a necessary condition for a correct
operation of the control system.
1. Electric connector - 2. Fuel outlet - 3. Fuel inlet.

Positioned at the inlet of the high pressure pump, it enables
to control the quantity of fuel feeding the pump according
to the controls received by the electronic Central Unit. In the
absence of control signal, the valve is normally open,
therefore the high pressure pump is in maximum delivery
condition.
The Central Unit sends a PWM control signal to the
controller, in order to choke in a greater or lesser way the
inlet section of the fuel to the high pressure pump.
This component cannot be replaced individually and
therefore must not be disassembled.
C87 ENT M38.10
High pressure pump During the induction stroke, the pumping, driven by the cam
located on the pump shaft, is fed through the pumping feeding
Figure 22 duct. The amount of fuel to send to the pumping is set by the
D-D section pressure control solenoid according to the PWM control
received by the electronic Central Unit. During the
compression stage of the pumping, the fuel reaches such a
pressure to open the delivery valve to common rail and
supply it through the outlet.
Figure 24
C-C section
1. Outlet for delivery to rail - 2. Delivery valve to rail -

3. Pumping - 4. Pump shaft - 5. Pumping feed duct -
6. Pressure control feed duct - 7. Pressure control
solenoid - 8. Fuel inlet from filter.
Figure 23
B-B section
1, 3, 6. Pumping feed ducts - 2. Pump lubrication ducts -
4. Pumping feed main duct - 5. Pressure control solenoid -
7. Control exhaust duct - 8. Low pressure limiter valve -
9. Fuel feed duct from filter - 10. Fuel outlet.
In the section of Figure 24 the low pressure fuel paths inside
the pump are represented. The pumping feed main duct (4),
pumping feed ducts (1, 3, 6), ducts used for pump lubrication
(2), the pressure control valve (5), the low pressure limiter
valve (8) and the fuel exhaust (10), are outlined. The pump
shaft is lubricated by the fuel through the delivery and
backflow (2) ducts. The control valve enables to define the
fuel amount by which feeding pumpings; the excess fuel
backflow through duct (9).
The lower pressure limiter valve in addition to operate as
manifold of the high pressure pump fuel drainage, also keeps
pressure constant at the regulator inlet.
C87 ENT M38.10
Figure 25
A-A section
1, 2. Fuel outlet ducts - 3. Fuel outlet from the pump with

connector for high pressure piping for common rail
In the section of Figure 27 the fuel flow through the pumping
outlet ducts is represented.
C87 ENT M38.10
Operation RAIL (PRESSURE ACCUMULATOR)

The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 26
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing 144833
in the rail.
The thereby-generated pressure makes the exhaust valve 1. Rail - 2. Fuel return - 3.Pipelines to injectors - 4. Fuel
open and the compressed fuel reaches the high-pressure supply to high pressure pump - 5. Pressure sensor -
circuit. 6. Overpressure valve
The pumping element compresses the fuel till the top dead The rail volume is of reduced sizes to allow a quick
center (delivery stroke) is reached. Afterwards, the pressure pressurisation at startup, at idle and in case of high flow-rates.
decreases till the exhaust valve is closed. It anyway has enough volume as to minimise use of plenum
The pumping element piston goes back towards the bottom chambers caused by injectors openings and closings and by
dead center and the remaining fuel is decompressed. the high-pressure pump operation. This function is further
enabled by a calibrated hole being set downstream of the
When the pumping element chamber pressure becomes less high-pressure pump.
than the supply pressure, the intake valve is again opened and
the cycle is repeated. A fuel pressure sensor (5) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
The delivery valves must always be free in their movements, feed-back information, depending on which the rail pressure
free from impurities and oxidation. value is checked and, if necessary, corrected.
The rail delivery pressure is modulated by the electronic
control unit, through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel. Electroinjector
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional Figure 27
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
114255
1. Fuel return hole - 2. Fuel supply

C87 ENT M38.10
EDC 7 Electronic Central Unit Air pressure/temperature sensor
Figure 28 Figure 29
08_053_C
08_024_C
It integrates a temperature sensor and a pressure one.

A. Connector for components assembled on engine - Positioned at the entrance of the intake manifold, it produces
A1. Electro-injector connector - a signal that is proportional to the absolute pressure value of
B. Connector for connections on the boat side. the intaken and supercharged air. This information, together
with the temperature, enables to adequate time and advance
The Electronic Central Unit (or ECU) is the component to the density of the comburent air, in order to reach the
operating the entire injection system. The process begins maximum thermodynamic efficiency avoiding harmful
with the start up of the main program and the run-up emissions and smoke. The pressure sensor is a solid state type
procedure that enables to recall into the RAM those data with an amplifier electronic circuit adjusted for thermic drift,
which, having characterized the engine management until the while the comburent air temperature sensor is a resistor with
previous stop, were stored into the non-volatile memory negative temperature coefficient.
E2PROM by the after-run procedure. After the run-up, the
test of the blink code light signalling EDC anomalies and the The pressure sensor is powered by a 5 V voltage and the
procedures which lead to the start of the engine, follow; output voltage is proportional to the pressure detected.
during such procedures the presence and consistency of the The temperature sensor has a resistance of about 2.5 k at
sensors electric signals are checked. The start of the 20 C temperature.
computer application routine of time and injection advance,
is preceded by the analogue-digital conversion of the data
coming from the sensors. At the end of the processing, the Atmospheric pressure sensor
final data still in digital format are transferred to the various Located inside the ECU, it produces a useful datum to
final and power stages, which will control (with the proper adequate injection procedures to the different positive
ways) the electro-injectors and the system actuators. displacement of the engine caused by the changes of the
environmental pressure conditions.
C87 ENT M38.10
Oil pressure/temperature sensor Crankshaft sensor
Figure 30 Figure 31
The body of the sensor is similar to that of the air 05_086_C

pressure/temperature sensor and the functions carried out
are analogous. It is assembled onto the engine oil filter
support, to measure the engine oil temperature and
pressure. The signal detected is sent to the ECU EDC that It is a variable reluctance inductive type, which generates
manages the low pressure indicator light. In this appliance, periodical alternate signals due to flow variation in the
pressure and oil temperature values are not shown by magnetic circuit produced inside the cranckshaft by the
instruments but the data are used by the ECU to carry out presence of a permanent magnet. It faces the pulley keyed on
the monitoring functions. In order to control the oil pressure the crankshaft to detect the passage of 58 tooths for every
gauge on the instrument panel, a specific sensor is used. revolution. The number of 58 tooths has been derived by a
constant pitch of 6 which would lead to a total of 60 tooths,
The pressure sensor is powered by a 5 V voltage and the 2 of which have been eliminated to generate an asimmetry of
output voltage is proportional to the pressure detected. The the signal that the ECU EDC uses as crankshaft positioning
temperature sensor has a resistance of about 2.5 k at 20C reference.
temperature. The signal of this sensor is processed in the ECU to assess:
- Engine rotation speed;
- Engine crankshaft acceleration;
- Angular position of the engine in respect to the TDC (top
dead center) of the pair of pistons.
It originates the information of the engine RPM on the
instrument and control panel.
The interruption of the signal of this sensor during engine
operation is provided by a recovery of ECU actuated using
the signal of the camshaft sensor, thus enabling the engine to
carry on operating. The solenoid is connected to terminals 1
and 2 and has a resistance of about 900 . Terminal 3 is
connected to the electric shielding and is insulated from the
sensor.
C87 ENT M38.10
Camshaft sensor Coolant temperature sensor
Figure 32 Figure 33
It is a resistor with negative temperature coefficient and is

positioned on the cylinder head at a short distance from the
05_086_C
thermostatic valve. It provides the indication of the metering
and the advance during the various engine strokes:
- Cold starting;
It is an inductive type like the previous one, and generates a - Putting in a steady state;
signal at the passage of 6 + 1 slots located on the toothed
wheel set into rotation by the camshaft. - Steady state;
Six reliefs equidistant among themselves provide the signal of - Overtemperature.
the following one another of the strokes in the 6 cylinders;
the seventh relief provides the synchronism signal enabling to The recognition of the overtemperature condition leads ECU
recognize the typical injection sequence: 1 - 4 - 2 - 6 - 3 - 5. to activate derating strategies in order to reduce heat intake
The interruption of this signal during the operation of the and protect engine efficiency.
engine is overcomed by having stored in ECU the injection The sensor has a resistance of about 2.5 k at the
sequence; if it is occurred before the starting it requires that temperature of 20 C.
a specific stroke recognition strategy is actuated.
The solenoid is connected to terminal 1 and 2 and has a
resistance of about 900 . Terminal 3 is connected to electric
shielding and is insulated from sensor.
C87 ENT M38.10
Fuel temperature sensor It provides the primary indication for the reckoning of the fuel
amount to be injected.
Figure 34 It is operated by the linkage of the controls on bridge or
assisted, produces in output a potentiometric variation of the
voltage which supplies it, in relation to the position where the
throttle lever is set.
A simultaneous safety indication is provided by the internal
switch to confirm the acceleration position: minimum - out
of minimum.
Such an indication in addition to the self-adative strategies of
the potentiometric signal, is used in the case of anomalies to
manage limp-home strategies, that enables to get back to
harbour notwithstanding the potentiometer being faulty.
Fuel pressure sensor on rail
Fitted to one end of the rail, it measures the pressure of the

existing fuel in order to determine the injection pressure.
The injection pressure value is used to control the injection
1. Fuel temperature sensor pressure and to determine the duration of the electrical
injection command
It is identical to the coolant temperature sensor and it is
positioned on the fuel filter bracket. It is powered at 5 V.
It provides a useful datum to recognize the fuel density that
feeds the electro-injectors in order to adequate the injection
time to the real quantity to be injected. The derating Figure 35
strategies, used when the fuel critical temperature is
overcome, are due to the sensitive reduction of its lubricating
action caused by the temperature increase. Sometimes these
strategies become evident by the limitation of the maximum
performance of the engine.
The ECU activates the relay for the filter heating element
with a fuel temperature 0 C and heats up + 5 C.
Temperature sensor has a resistance of about 2.5 , at 20 C.
Throttle lever position
Figure 36 114620
Ref Description
1 Earth
2 Pressure
3
Power supply
C87 ENT M38.10
SYSTEM FUNCTIONS Metering and fuel injection

By means of the computer electronic management it is It is carried out by the span of time of the injectors electric
possible to actuate in fast sequence both primary functions control fed by the pressurized fuel in the common rail
such as metering computation and injection advance and distributor.
secondary ones, only necessary in special conditions. Fuel pressure in the common rail distributor is made to
Metering and advance, actuated three times per every change according to the performance goals required from the
crankshaft revolution, are selectively calculated cylinder by engine.
cylinder at every injection, while secondary functions as the The primary datum of the amount of fuel to be injected is
acceleration management or heating element on fuel filter calculated according to the information of:
activation are controlled only when necessary.
Moreover the electronic unit is programmed to carry out - Throttle position;
continuous checks on presence and consistency of the - Engine number of RPM.
signals originated from the system sensors, to timely notify
the onset of faults or actuate the exclusion of a datum This datum is further adjusted according to the data of:
whenever its content is in contrast with the logic sequence - Comburent air pressure and temperature;
of the events occurred up to that moment.
- Fuel temperature;
Run up - Engine coolant temperature.
Immediately after having electrically powered up the system It may be modified by linearization for acceleration gradient,
(key is in the ON position), the central unit before setting on the minimum RPM, to avoid overspeed or to control limit
the cranking motor, transfers into the main working memory condition of engine operation.
data which have characterised the best engine operation The span of time of the electro-injector control which sets
during the previous operation period; they represent the the real quantity injected is, moreover, related to the fuel
progressive engine ageing and they progressively evolve with pressure datum detected on the common rail distributor and
usage. the battery voltage.
By using this function, engine management is always Only in case of anomalies which entail serious damages for
optimized even from the first operation stages, indipendently the engine, injection time zeroing is reached.
from the usage conditions of the engine.
The data transferred after the run-up are those stored after Injection advance management
the last engine stop during the after run function. It is obtained by changing in the span of time of one revolution
Starting of the crankshaft the instant of the electric control beginning
of the electro-injectors.
It is the management stage of the engine functions The values actuated may vary from one injection to the next
characterised by the adotpion of useful strategies to a fast and in the same way as for the metering varied among the
reaching of the endothermic engine functions. cylinders.
Among the restrained signals the most evident is the The parameters affecting the injection advance are:
recognition of the throttle position that does not require to
be operated until the starting procedure is concluded. - Throttle position;
- Engine RPM;
- Comburent air temperature and pressure;
- Fuel temperature;
- Coolant temperature.
The values are determined experimentally in order to obtain
the best performance and at the same time complying with
containment goals on acoustic and fumes emissions.
A further dynamic adjustment during the acceleration phase
gives the engine a greater static torque.
The information to check the actuated value obtained in
loop is provided by the electro-injector solenoid
impedance change.
C87 ENT M38.10
Pre-injection EDC indicator light

This term indicates the delivery of a limited amount of fuel It is located on the instrument and control panel, is directly
that is obtained in the short interval of opening and closing controlled by the EDC system from the central unit. It is
of the spray-nozzle metering rod, before the main injection. normally off, it will come on for an instant immediately after
Pre-injection is programmed in the ECU and it is possible up having supplied the system by means of an efficiency test.
to 2,000 RPM. Its purpose is to limit the pressure increase If lit, the EDC indicator shows a likely anomaly of the injection
gradient within the combustion chamber to reduce its peaks system or an irregular engine operation or of one of its
and contain typical noise of the direct injection engines. machine parts.
The amount of fuel injected is an integral part of the main Fuel heating
metered injection.
It assures a correct density of the fuel even at low
Injection pressure modulation temperatures, improving atomization in order to obtain a
The best and more reliable torque and power delivery, better gradient smoke and emissions.
complying with fumes and acoustic emission containment, is The heating element is activated on the filter according to the
made possible by having a high pressure fuel delivery and by temperature detected.
using injectors having a high atomization. In order to conform Linearization of the acceleration gradient
fuel metering with the high dynamics required by the engine
control, apart from managining the injection time, managing The exhaust and acoustic noxious emissions containment has
the pressure of the fuel injected is also necessary. been obtained by implementing strategies especially to
This goal is obtained in loop by using the datum supplied by control the injection required for accelerations. Management
the pressure sensor located on the common rail distributor. of the fuel metering and advance, during transient states, has
been obtained by devising experimental progression modes
Idling adjusting stored in the central unit.
This function enables to obtain a constant and repeatable Balance of the cylinder torque delivery
RPM notwithstanding the changing of the operational
environmental conditions. The adjustment is obtained by It contributes to reduce vibrations and equilibrates its
managing metering and the injection beginning instant operation.
according to the processing of the information produced by It is obtained by controlling delivery and injection advance
the sensors. cylinder by cylinder; in such a way it is possible to adequate
If battery voltage is below efficiency rating, ECU increases crankshaft angular acceleration produced by each
rotation to improve alternator recharging. combustion to equal ratings.
Cylinders balance can be carried out only at idle speed, due
Self-diagnosis to software structure complexity, but data thus gathered with
It is the constant check of the presence of the electrical a wise adaptation, can be used for higher speed too.
signals sent by the sensors or delivered to actuators. In the Rotation speed control
case of anomalies being detected, it enables the electronic
unit to process data according to a recovery programme. It represents the electronic equivalent of the speed controls
of the traditional injection pumps.
The central unit not only checks the efficiency of the sensors, Like the latter it has the following adjustment characteristics:
actuators and wiring connected to them, but also checks a
consistency evaluation of the signals and the information - Minum and maximum;
deducted from them. - Every speed.
It is possible to recognise an inconsistency and not use an
invalidated datum replacing it with that one predefined by Top speed limitation
means of comparison with pre-programmed limit
It preserves the efficiency of the engine operation by not
parameters or by assessing their increasing or decreasing allowing overspeed even if accidental.
gradient. The recovery procedure is integrated by the Limitation strategies are actuated in the following ways:
storing of the codes identifying the errors detected. These
codes can be decoded by using diagnostic computerized - When the first threshold is overcome, fuel delivery
appliances or by means of a blinking light named blink code. reduces progressively;
- When the expected top speed has been reached, fuel
delivery is zeroed.
C87 ENT M38.10
Cut off
It consists of non injecting fuel during the engine deceleration
phase. The function is operating until the idle speed is
reached below which it would be impossible to restore
engine thermic operation.
Derating
It can be considered as a recovery programme. It does not
produce a storage of an anomaly record. It is caused by the
recognition of fuel high temperature, coolant, or comburent
air. Derating consists of reducing the torque delivered by the
engine to preserve it from operation inefficiency. It takes
place when overcoming preset thresholds, in a way
proportional and gradual to the amount of the overcoming
of parameter; it does not entail fault signalling on the
instrument panel.
Recovery
It is a special way of control and management characterised
by the adoption of a number of strategies which enable the
system to operate even in the case selfdiagnosis has
recognized the presence of anomalies. In the majority of
cases seafaring can be continued regularly or with reduced
performance.
Adopting a recovery strategy entails the storing of an
anomaly code and the corresponding limitation of the
maximum power rating delivered by the engine.
The power rating limitation due to recovery strategy is active
up to the stopping of the engine even if the anomaly detected
is not there anymore. The blink code light on the instrument
and control panel will turn on only for the most serious
events.
After run
The stage following after every engine stop. It is characterised
by the delay in deenergizing the main supply solenoid
contained inside the ECU EDC. During this phase the central
unit is still powered for some seconds, during which the data
that have characterised the optimized management of the
engine up to that moment, are transferred from the main
volatile memory to the EEPROM non volatile memory; these
data will then be available for the next starting.
These data can be summarised into:
- Management modes (idle speed, torque delivery balance,
smoke limit...);
- Threshold setting min/max of signal recognition;
- Fault memory.
At every start up it is important to have available the data that
optimize the management and the engine behaviour in terms
of TORQUE AND POWER DELIVERY. It is therefore
mandatory to use engine stopping strategies (e.g. battery
disconnection) not different from those prescribed by the
manufacturer (key in OFF position) or which may prevent
the correct execution of the after run function.
C87 ENT M38.10

C87 ENT M38.10
OCTOBER 2010 TECHNICAL DATA C87 ENT M62.10 2.35
SECTION 2
TECHNICAL DATA
Page
SPECIFICATIONS
C87 ENT M38.10 . . . . . . . . . . . . . . . . . . . . . . 37
SPECIFICATIONS
C87 ENT M62.10 . . . . . . . . . . . . . . . . . . . . . . 40
C87 ENT M38.10
2.36 C87 ENT M62.10 TECHNICAL DATA OCTOBER 2010

C87 ENT M38.10
SPECIFICATIONS C87 ENT M38.10
Cycle 4-Stroke Diesel

Charge Supercharged and intercooled
Injection Direct
Number of cylinders 6 in line
Bore mm 117
Stroke mm 135
Total displacement cm3 8710
Compression ratio 16 to 1
Direction of rotation, flywheel side counterclockwise
Minimum idling rpm rpm 600
Maximum engine rpm, no load rpm 2200
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic) degrees/360 + 20
Maximum transverse in continuous operation (static + dynamic) degrees/360 22 30'
Longitudinal for oil level check with standard dipstick degrees/360 0 to +10
Supercharge
Turbocompressor with water-cooled body HOLSET HX 55WM
Maximum pressure bar 2.6
Lubrication
Oil type ACEA E3/E5 (URANIA LD5)
Oil compliant with specifications SAE 15W-40
Total oil capacity on first filling liters (kg) 29 (26)
Total oil capacity with sump at minimum level liters (kg) 15.5 (14)
Total oil capacity with sump at top level liters (kg) 24 (21.5)
Oil pressure, warm engine, minimum idling rpm bar 2
Oil pressure, warm engine, maximum rpm bar 5.0
Maximum allowed temperature C 105
Oil dipstick valid for static inclination degrees/360 0 to + 10
Fuel supply
Fuel oil compliant with standard EN 590*
Low pressure transfer pump gear pump
Flow rate at maximum rpm kg/h 59.2
Fuel return flow rate to tank kg/h -
Filtering: pre filter m 36.5
Filtering: filter m 5
CAUTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low tem
peratures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the climactic
and geographic conditions of the various Countries be distributed.
C87 ENT M38.10
Injection system
Type HPCR
System Bosch EDC7 UC31
Maximum injection pressure bar 1400
Low temperature starting

Allowed, without external aids, down to C -15
With electrical heating of intake air (optional), down to C -25
With additional external heater, down to C -30
Cooling
Closed coolant loop with 50% mixture of water/Paraflu 11 or
sea water heat exchanger equiv. Compliant with SAE J 1034
specification
Total coolant quantity liters 38
Engine-only capacity liters 16
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm l/h -
Temperature regulation with thermostatic valve
Initial opening C 68 78
Sea water line forced circulation
Sea water pump centrifugal self-priming
Max. pump capacity l/h -
Exhaust gas expulsion

Optional stack
Optional riser
Electrical system
Nominal voltage Vcc 24
Self-regulated alternator:
Voltage Vcc 28
Maximum current intensity A 90
Electrical starter motor:
Nominal voltage V 24
Absorbed electrical power W 4500
Recommended batteries capacity Ah 120
Current discharge at - 18 C (SAE J 537) A 900
C87 ENT M38.10
Drive train coupling

Flywheel diameter mm (inches) 355 (14)
Flywheel case type SAE 1
Weights
Without liquids and without gearbox kg 940
Dimensions
Figure 1
143679
Sizes in mm
C87 ENT M38.10
SPECIFICATIONS C87 ENT M62.10
Cycle 4-Stroke Diesel

Charge Supercharged and intercooled
Injection Direct
Number of cylinders 6 in line
Bore mm 117
Stroke mm 135
Total displacement cm3 8710
Compression ratio 16 to 1
Direction of rotation, flywheel side counterclockwise
Minimum idling rpm rpm 600
Maximum engine rpm, no load rpm 2700
Allowed engine inclination angles
Maximum longitudinal in continuous operation (static + dynamic) degrees/360 + 20
Maximum transverse in continuous operation (static + dynamic) degrees/360 22 30'
Longitudinal for oil level check with standard dipstick degrees/360 0 to +10
Supercharge
Turbocompressor with water-cooled body HOLSET HX 55WM

Maximum pressure bar 2.2
Lubrication
Oil type ACEA E3/E5 (URANIA LD5)

Oil compliant with specifications SAE 15W-40
Total oil capacity on first filling liters (kg) 28.5 (25.5)
Total oil capacity with sump at minimum level liters (kg) 15.5 (14)
Total oil capacity with sump at top level liters (kg) 24 (21.5)
Oil pressure, warm engine, minimum idling rpm bar 2
Oil pressure, warm engine, maximum rpm bar 5.0
Maximum allowed temperature C 105
Oil dipstick valid for static inclination degrees/360 0 to + 10
Fuel supply
Fuel oil compliant with standard EN 590*
Low pressure transfer pump gear pump
Flow rate at maximum rpm kg/h 104.8
Fuel return flow rate to tank kg/h -
Filtering: pre filter m 36.5
Filtering: filter m 5
CAUTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low tem
peratures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the climactic
and geographic conditions of the various Countries be distributed.
C87 ENT M38.10
Injection system
Type HPCR
System Bosch EDC7 UC31
Maximum injection pressure bar 1600
Low temperature starting

Allowed, without external aids, down to C -
With electrical heating of intake air (optional), down to C -25
With additional external heater, down to C -30
Cooling
Closed coolant loop with 50% mixture of water/Paraflu 11 or
sea water heat exchanger equiv. Compliant with SAE J 1034
specification
Total coolant quantity liters 38
Engine-only capacity liters 16
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm l/h 42300
Temperature regulation with thermostatic valve
Initial opening C 68 78
Sea water line forced circulation
Sea water pump centrifugal self-priming
Max. pump capacity l/h -
Exhaust gas expulsion

Optional stack
Optional riser
Electrical system
Nominal voltage Vcc 24

Self-regulated alternator:
Voltage Vcc 28
Maximum current intensity A 90
Electrical starter motor:
Nominal voltage V 24
Absorbed electrical power W 4500
Recommended batteries capacity Ah 120
Current discharge at - 18 C (SAE J 537) A 900
C87 ENT M38.10
Drive train coupling

Flywheel diameter mm (inches) 355 (14)
Flywheel case type SAE 1
Weights
Without liquids and without gearbox kg 970
Dimensions
Figure 1
143679
Sizes in mm
C87 ENT M38.10
OCTOBER 2010 ELECTRICAL EQUIPMENT C87 ENT M62.10 3.43
SECTION 3
ELECTRICAL EQUIPMENT
Page
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . 45
PARTS AND COMPONENTS ENGINE . . . . 50
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . 52
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . 53
Mitsubishi 90A . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ELECTRICAL STARTER ENGINE . . . . . . . . . . 54
Nippondenso model . . . . . . . . . . . . . . . . . . 54
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . 54
CONNECTIONS OF THE CENTRAL ELECTRONIC

UNITCONVERTER MODULE . . . . . . . . . . . . 55
Identification of terminal function . . . . . . . . . . 55
EQUIPOTENTIAL CONNECTIONS TO ENGINE

GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
C87 ENT M38.10
3.44 C87 ENT M62.10 ELECTRICAL EQUIPMENT OCTOBER 2010

C87 ENT M38.10
Figure 1
10_032_C
1. Eelectronic Unit - 2. Mm Connector - 3. Wiring harness to be manufactured by the yard - 4.M Sensor for the presence
of water in the fuel - 5. Sedimenting pre-filter - 6. Power line for electric starter motor and alternator - 7. Relay box -
8. JECCM and JECCF connectors - 9. Analog to digital converter module -10. JG connector - 11. JSV connector -
12. JQA connector set for connection to the main analog instrument panel - 13. Connector JE - 14. Connector JH -
15. Connector JQ - 16. Connector J3 - 17. Connector J4 - 18. Connector - 19. Connector J2. - 20. Extension cables available
in 3,5,7,10 and15
The electrical equipment of the engine comprises a series of Together with the coupling of all the wiring connectors it is
components provided separately from the engine to enable necessary to carry out the connection wiring (3) for the
an easy and diversified installation, according to the Yard's water in fuel sensor (4), the power network and the
design choices. The need to make accessible, at sea or connection of the accumulator with the engine wiring, in
underway, the controls to the electrical components and to order to complete the installation In order to activate the
the connector for diagnostics contained in the relay box may function which stops the engine in case of excitation, it is
be met through different installation arrangements. necessary to connect the JECCM and JECCF connectors
with each other.
C87 ENT M38.10
Engine cable
Figure 2
143680
1. Electroinjector - 2. Wires passage - 3. Coolant temperature sensor - 4. Oil pressure/temperature sensor -

5. Combustion air pressure/temperature sensor - 6. EDC connector A1 - 7. EDC connector A -
8. Fuel temperature sensor - 9. Camshaft sensor - 10. Crankshaft sensor - 11. Rail pressure sensor -
12. Pressure regulating electrical valve.
C87 ENT M38.10
Engine cable wiring diagram

Figure 3
10_034_C
EDCA. EDC connector A - C. Camshaft sensor - B. Crankshaft sensor - VS. Oil pressure/temperature sensor -
HP. Combustion air pressure/temperature sensor - ZH. Fuel high-pressure pump sensor - A. Fuel temperature sensor -
F. Coolant temperature sensor - PR. Rail pressure sensor - 1. Electroinjector - EDCA1. EDC connector A1
3.48
Figure 4
C87 ENT M62.10
C87 ENT M38.10
Wiring layout engine

A. Fuel temperatu
1. Connector JB - 2. Oil filter clogging (U) - 3. Connector CAN BUS electronic handwheels (JD)- 4. Connector for RINA (JR) - 5. Water in fuel prefilter sensor
(M) - 6. Low coolant level sensor (J) - 7. Electrical oil pump (PO) - 8. Electrical valve oil charge/discharge (EC) - 9. Overspeed pick-up (BA) - 10. Exhaust gas
temperature sensor for gauge (O,O1) - 11. Accelerator potentiometer position sensor (PA) - 12. EDC connector B (EDC B) - 13. GN. Neutral gear sensor -
14. Connector for inverter (JINV) - 15. Oil pressure temperature sensor gear (VI) - 16. Oil temperature sensor gear box (SI) - 17. Clogging fuel filter sensor
(Z) - 18. Air filter clogging (K) - 19. Air filter clogging (K1) - 20. Blow by clogging sensor (X) - 21. Starter motor (MM) - 22. Grid heater relay (GH) -
23. Electrical valve by-pass (GX) - 24. Alternator (GG) - 25. Alternator B+ (B+).
143681
OCTOBER 2010
Figure 5
OCTOBER 2010
Wiring layout engine

JB. Connector JB - JINV Connector for inverter - JD Connector CAN BUS electronic handwheels - JR. Connector for RINA -
K1 Air filter clogging - K. Air filter clogging - Z. Clogging fuel filter sensor - U. Oil filter clogging - O1. Exhaust gas temperature sensor for gauge -
O. Exhaust gas temperature sensor for gauge - X. Blow by clogging sensor - SI. Oil temperature sensor gear box - VI. Oil pressure temperature sensor gear -
J. Low coolant level sensor - M. Water in fuel prefilter sensor - GG. Alternator - B+. Alternator B+ - EDC B. EDC connector B - PA. Accelerator
C87 ENT M62.10
C87 ENT M38.10
potentiometer position sensor - GN Neutral gear sensor (in installation with no sensor, do not remove the cap of the GND connector to avoid compromising
start engine function) - GH. Grid heater relay - GX. Electrical valve by-pass - BA. Overspeed pick-up - MM. Starter motor - PO. Electrical oil pump -
EC. Electrical valve oil charge/discharge
3.49
10_035_C
C87 ENT M38.10
PARTS AND COMPONENTS ENGINE
Figure 6
10_029_C
1. Air filter - 2. Common rail high pressure injection pump - 3. Air/sea-water heat exchanger -
4. Air pressure/temperature sensor - 5. Chimney exhaust gas (pot.) - 6. Engine coolant-sea water heat exchanger -
7. Switchable oil filters (only for version C87 ENT M38.10) - 8. Oil filter clogging - 9. Coolant temperature sensor -
10. Thermostatic valve - 11. Alternator - 13. Inverter oil heat exchanger - 14. Electrical starter motor -
15. Sea water pump - 16. Fuel Filter.
C87 ENT M38.10
Figure 7
10_030_C
1. Connector JB - 2. Coolant expansion tank - 3. Coolant refill cap - 4. Coolant low level sensor -
5. Lifting U-bolt - 7. Oil refill cap - 8. Clogged fuel filter sensor - 9. Clogged air filter sensor - 10. Cooled turbo-charger -
11. Exhaust gas and sea water discharge - 12. Camshaft sensor - 13. Accelerator potentiometer position sensor -
14. Oil dipstick - 15. Cooled exhaust manifold - 16. Oil sump emptying pump.
C87 ENT M38.10
ELECTRICAL SYSTEM
Figure 8
09_061_N
1. Equipment power supply - 2. Batteries -

3. Electric starter motor - 4. Alternator - 5. Grid heater
The connection of the +B terminal of the alternator to the
positive+30 terminal of the electric startermotormust be
achieved with a conductor having a cross section of at least
40 mm2. The connection of the positive +30 terminal of the
electric starter motor to the positive pole of the battery,
achieved with a conductor having a cross section of at least
95 mm2, allows to obtain, as shown in the figure, the
simultaneous connection of the alternator to the battery.
The connection between the engine ground and the negative
pole of the battery must be achieved according to the
guidelines provided in the Engine electrical ground
paragraph.
The connection (*) between alternator terminal B- and
terminal 31 of the starter motor must be made only in the
case of an isolated terminal system and the cross-section
must be equal to 40 mm2.
The connection (**) for the thermal starter relay is the
responsibility of the customer and the cross-section must be
equal to at least 16 mm2.
CAUTION
If magneto-thermal protecting breakers are inserted, they
must not be used to stop the engine and in any case they
must be activated only a few seconds after shut-down.
C87 ENT M38.10
ALTERNATOR
Figure 9
05_093_C
Mitsubishi 90A Figure 10

+B. (24 V) Power supply output terminal
S. (Sense) Reference voltage of battery charge status Ambient temp. 25 C
(connected to +B terminal or to be
connected to the positive pole of the battery
in case of remote installation of the battery);
IG. (Ignition) Regulator enabling signal (connected to
Output current (A)
voltage +, driven by key switch);

L. (Lamp) Power supply voltage of recharge/alarm Ambient temp. 90 C
indicator light located on the panel.
81797
Alternator speed (rpm x 1000)
Specification
CHARACTERISTIC CURVES
Nominal voltage 28.3 0.5V (20C)

Nominal current 90 A
Rpm for min power ~ 1800 rpm
Rpm for max power ~ 5000 rpm
Polarity negative ground
Rotation clockwise viewed from
pulley
Belt poly V
Belt tension 730 N
Weight 7.0 kg
C87 ENT M38.10
ELECTRICAL STARTER ENGINE
Figure 11
Engine
electrical
ground
connection
point
+50 Starter 81799

control
"Nippondenso" model
Specification Figure 12
Nominal power 5.5 kW

Nominal voltage 24V
Polarity negative ground
Engagement circuit positive command
Rotation clockwise viewed
from pinion end
Weight ~ 10.5 kg
Operating voltage 26V MAX (20 C)
Water resistance spray test based on
JIS D0203 SI
Current (A) 81800
CHARACTERISTIC CURVES
Condition (20 C) Voltage (V) Current (A) Speed (rpm) Torque (Nm)
No load 23 120 3800 -
Load 16 690 900 49
Stall 6 1260 0 73.5
C87 ENT M38.10
CONNECTIONS OF THE CENTRAL ELECTRONIC UNITCONVERTER MODULE
Figure 13 Identification of terminal function

EDC A Connector
Figure 14
08_024_C
A. 36 poles connector - A1. 16 poles connector -

B. 89 poles connector.
The connection of the central electronic unit, the ECU, to
the components of the EDC system is achieved by means of
three connectors so as to subdivide the wiring harnesses,
thereby favoring a quicker identification of the lines during
testing operations.
The different connectors are polarized and provided with
levers to favor the connection and disconnection operations
and assure proper coupling.
They are dedicated to the following functions:
- Connector A for engine mounted components;
Pin Function
- Connector A1 for electro-injector connection; 1 -
- Connector B for boat side connections. 2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 Timing sensor
10 Timing sensor
11 -
12 Negative for rail temperature and pressure sensor
13 Positive for rail temperature and pressure sensor
14 Signal from rail temperature and pressure sensor
15 Coolant temperature sensor
16 -
C87 ENT M38.10
Pin Function Identification of terminal function

17 - EDC A1 Connector
18 Signal from fuel temperature sensor
19 Engine rpm sensor Figure 15
20 -
21 -
22 -
23 Engine rpm sensor
24 Negative for engine oil pressure and temperature
sensor
25 Negative for air temperature and pressure sensor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature sensor
29 -
30 -
31 -
32 Positive for engine oil pressure and temperature
sensor
33 Positive for air temperature and pressure sensor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor
Pin Function
1 Injector cylinder 5
7 -
8 -
9 Pressure regulator
10 Pressure regulator
C87 ENT M38.10
Identification of terminal function

EDC B Connector
Figure 16
Pin Function Pin Function

1 - 19 -
2 Supply 20 -
3 Supply 21 Neutral switch input
4 - 22 -
5 Ground 23 -
6 Ground 24 -
7 - 25 -
8 Supply 26 -
9 Supply 27 -
10 Ground 28 -
11 Ground 29 Digital round
12 Positive for grid heater relay 30 -
13 Positive for fuel filter heating relay 31 -
14 - 32 Signal for start engine from box relay
15 - 33 -
16 - 34 Line CAN - L
17 Starting relay negative voltage 35 Line CAN - H
18 -
C87 ENT M38.10
Pin Function Pin Function

36 Negative voltage for fuel filter heater switch 63 -
37 Starting relay positive voltage 64 -
38 - 65 -
39 - 66 Neutral switch input
40 Positive voltage +15 under lock 67 -
41 - 68 -
Negative voltage from sensor detecting water in the 69 -
42
pre-filter 70 -
43 - 71 -
44 - 72 -
45 - 73 -
46 - 74 -
47 Signal for stop engine from box relay 75 Negative for grid on heater
Negative voltage from accelerator pedal idling 76 -
48
switch
77 Supply voltage for accelerator potentiometer
49 -
78 Negative for accelerator potentiometer
50 -
79 Signal from accelerator potentiometer
51 -
80 -
52 -
81 -
53 -
82 -
54 -
83 -
55 -
84 -
56 -
85 Signal for start engine from box relay
57 -
86 -
58 -
87 -
59 -
88 -
60 -
89 ISO K interface
61 -
62 -
C87 ENT M38.10
EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND

To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean and
not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
Figure 17
147000
1, 2, 3, 4. Copper braids
CAUTION
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean
and not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
C87 ENT M38.10

C87 ENT M38.10
OCTOBER 2010 DIAGNOSTICS C87 ENT M62.10 4.61
SECTION 4
DIAGNOSTICS
Page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . 63
PT - BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
GUIDE TO SYMPTOM DIAGNOSIS . . . . . . . 65
FAULTS CODE - EDC 7 UC31 . . . . . . . . . . . 69

C87 ENT M38.10
4.62 C87 ENT M62.10 DIAGNOSTICS OCTOBER 2010

C87 ENT M38.10
FOREWORD
A successful troubleshooting is carried out with the Every time there is a breakdown claim and this breakdown
competence acquired by years of experience and attending is actually detected, it is necessary to proceed inquiring the
training courses. electronic unit in one of the ways indicated and then
proceed with the diagnostic research making trials and tests
When the user complains for bad efficiency or working
in order to have a picture of the working conditions and
anomaly, his indications must be kept into proper
identify the root causes of the anomaly.
consideration using them to acquire any useful information
to focus the intervention. In case the electronic device is not providing any indication,
it will be necessary to proceed relying on the experience,
Using FPT processing instruments, it is also possible to
adopting traditional diagnosis procedures.
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input
an enquiry relying on memory files, in order to achieve any
further necessary information to identify the origin of the CAUTION
anomaly.
Any kind of operation on the electronic center unit must
be executed by qualified personnel, duly authorized by FPT.
Any unauthorized tamper will involve decay of after-sales

service in warranty.
C87 ENT M38.10
PT - BOX
PT - BOX is a test tool to be connected to a Personal Computer.
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator -
5. Serial port indicator - 6. Error indicator - 7. CAN line indicator -
8. Line K indicator for automatic management
With the PT-BOX you can perform:

- Basic testing: central unit ID reading, failure memory reading, parameter reading, failure memory clearing and Flight
Recorder memory reading;
- Active testing: main component testing (actuators, contactors, etc..);
- Flight Recorder reading;
- ECU acknowledgement of replaced electronic components;
- 2nd level and PTO programming;
- Parameter acquisition during operation tests.
GUIDE TO SYMPTOM DIAGNOSIS
OCTOBER 2010
Blink Symptom Part Possible cause Recommended tests or action

Code
NO Engine does not start Batteries - Low charge - Recharge (disconnecting system
- Faulty terminal connections wiring)
- Clean, check, tighten terminals or
replace them
NO Engine does not start Electrical starter motor - Malfunction - Check
- Faulty terminal connections - Clean, check, tighten terminals
NO Engine does not start Relay to control power - Malfunction - Check supply wiring
supply to terminal 50 of - Check main relay, replace
the electric starter motor
(contained in the relay
box)
NO Engine does not start Fuel feed pump - Priming incorrect (air leaking inside) - Check seal on intake branch
- Check pressure
DIAGNOSTICS
NO Engine does not start Fuel circuit - Incorrect filling (air in fuel circuit) - Check seal
- Bleed circuit
NO Engine does not start Fuel filter and pre-filter - Filter and pre-filter clogged - Check reservoir
- Replace
NO Engine does not start Electrical grid heater (if - Malfunction - Check supply and earth connection
present), at temperatures - Faulty terminal connections - Carry out active diagnosis
lower than 0 C.
C87 ENT M62.10
C87 ENT M38.10
4.65
GUIDE TO SYMPTOM DIAGNOSIS 4.66

Code
C87 ENT M62.10
C87 ENT M38.10
NO Engine overheats Coolant level - Below MIN level - Check for leaks
- Top up correct level
NO Engine overheats Coolant pump drive belt - Loose tension - Check tension
- Wear - Replace
- Verify liquid spillage on the belt
NO Engine overheats Coolant pump - Malfunction - Check belt tension
- Replace
NO Engine overheats Thermostatic valve - Locked, closed or only partially open - Check coolant liquid
- Replace
NO Engine overheats Coolant-sea water heat - Clogged - Clean or replace
exchanger
NO Engine overheats Air filter - Clogged - Check filter clogged indicator
- Replace filter
DIAGNOSTICS
NO Engine overheats Cylinder head gasket - Compression leaking from cylinder head gasket - Check water circuit pressure
- Replace head gasket
OCTOBER 2010
GUIDE TO SYMPTOM DIAGNOSIS
OCTOBER 2010

Code
NO Poor performance Fuel circuit - Reservoir net filter clogged - Replace clogged filters
- Fuel prefilter clogged - Check intake seals
- Fuel filter clogged - Check pressure relief valve on the fuel
- Air in fuel circuit gear pump
- Fuel pressure too low - Check the integrity of the fuel gear pump
- Heavy fuel leakage
NO Poor performance Injectors - Malfunction - Check for fuel presence in engine
- Fuel leaking from seal rings - Call FPT and follow their instructions to
replace the injectors
NO Poor performance Air filter - Clogged - Check filter clogged indicator
- Replace filter
NO Poor performance Gas exhaust system - Leaks from exhaust manifold - Check and remove cause of leak
NO Poor performance Turbocompressor - Blades inefficient - Check parts and lubrication circuit
- Bearings inefficient - Replace
NO Poor performance Control cams - Wear - Check, replace
DIAGNOSTICS
- Incorrect timing - Check, restore

NO Poor performance Valves - Excessive or no clearance - Check, restore correct clearance
NO Poor performance Intake air pressure sensor - Output signal too low (below to the pressure - Using a multimeter on the component,
value) check the output voltage and refer to a
manometer
NO Poor performance - Intake air temperature - Output signal too high - Using a multimeter on the component,
sensor check the resistance and refer to a
- Water temperature thermometer
sensor
- Fuel temperature sensor
C87 ENT M62.10
C87 ENT M38.10
4.67
GUIDE TO SYMPTOM DIAGNOSIS 4.68

Code
NO The engine emits greywhite Water in cylinders - Leakages from cylinder gasket - Check level and pressurization of water
C87 ENT M62.10
C87 ENT M38.10
smoke - Leakages from injector sleeves circuit

- Water in intake system - Check fuel tank, clean as required
- Water in fuel - Check water in fuel sensor
The engine emits blue Oil in cylinders - Excessive oil consumption - Check lubrication oil consumption
smoke - Oil leaking in turbocompressor - Overhaul
- Oil leaking from valve guides
NO Engine stops Fuel reservoir - Fuel reservoir empty - Refill and bleed fuel circuit
NO Engine stops Net filter - Filter clogged - Clean, replace
Prefilter
Fuel filter
DIAGNOSTICS
NO Engine stops Fuel circuit - See item Poor performance - See item Poor performance
OCTOBER 2010
C87 ENT M38.10
FAULTS CODE - EDC 7 UC31

CAUTION
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
Legend:
MAX = 3 Electronic control unit has read value OVER range

MIN = 4 Electronic control unit has read value UNDER range
SIG = 2 Electronic control unit has read a FAILURE of signal
NPL = 12 Electronic control unit has read of UNPLAUSIBILITY of signal
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
Vehicle 1 (Sensors/Plausibility checks)
111 x x x x Fault path 1 for vehicle Speed sensing
211 x x x x Fault path 2 for vehicle Speed sensing(CAN)
311 x x x Fault path 3 for veh. Speed (max.pulse width)
112 x Accelerator Pedal 1
212 x x x Accelerator Pedal 2
113 x Accelerator Pedal and brake not plausible
114 x x x Multiple State Switch
116 x x Main clutch signal
117 x x Brake signal
118 x Engine brake preselection switch status
119 x No terminal 15 signals detected
11A x Terminal 50 always pressed
11B x High resolution wheel speed CAN message
21B x Vehicle dynamics control unit CAN message
11C x Water in fuel
21D x x x x Catalyst ageing limit exceeded
31D x x x x DCU state monitoring
11E x NH3Slip
21E x x x x Catalyst efficiency lower than first Nox prediction threshold level
31E x x x x Catalyst efficiency lower than first Nox prediction threshold level
41E x x x x Catalyst presence monitoring
11F x x x x Plausibility check of catalyst system
21F x x x x Boost pressure actuator current monitoring
31F x x x x Too high efficiency of catalyst system
Vehicle 2 (Lamps/relays/actuators)
121 x x x x Adjustable speed limit lamp
122 x x x x Power stage fault status for MIL
123 x x x x Power stage for system lamp
124 x x x x Cold start lamp
224 x x x x Coolant temperature lamp
Main relay defect (for High press pump P340/for engine brake
125 x x
decompr.valve P342)
225 x Interrupted afterrun
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
126 x x Battery voltage fault
127 x x Eng.brake decompr.valve
128 x Main relay SCBatt (Lambda H./Grid H./Batt.switch)
228 x Main relay SCGND (Lambda H./Grid H./Batt.switch)
129 x x Main relay 3 (A/C compr./fuel filter heater)
12A x x Main relay 4 (Exhaust valve eng.brake flap)
22A x x x x Particulate filter lamp
12B x x x Power stage air heater 1 actuator
12C x x x Power stage air heater 2 actuator
12D x x Air heater test switch on (voltage<low thresh.)
22D x x Air heater test switch off (voltage>high thresh.)
12E x Grid heater always switched on
12F x x Air condition power stage CAN message
Engine 1 (Temperature and Pressure Sensors)
131 x x x x Coolant temperature sensor
132 x Coolant temperature sensor dynamic test
232 x Coolant temperature sensor absolute test
332 x x Engine temperature check
133 x x x Boost Temp. Signal
134 x x x x Boost pressure sensor
135 x x Fuel Temp. Signal
136 x x Rail pressure sensor CP3
236 x x x Rail pressure sensor offset monitoring
137 x x x Rail pressure relief valve
138 x x x x Oil Pressure Sensor
238 x Oil Pressure too low
338 x x x x Oil Pressure sensor lamp
13A x x x x Oil Temp. Sensor
23A x Oil Temperature above normal
13C x x x Atmospheric Temperature Sensor (Humidtiy?)
13D x x x Fuel pressure sensor
23D x x Fuel pressure sensor dynamic plausibility test
Engine 2 (Speed sensing/actuators)
141 x x Crankshaft sensor failure
142 x Running with camshaft sensor only
143 x x Camshaft sensor failure
144 x x Offset between camshaft and cranksh.
145 x x x x Power stage Fan actuator
146 x x Power stage Fan 2 actuator
147 x x Fan speed sensor signal
148 x x x x Air condition power stage
149 x x x x Fuel filter heating output
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
14A x Engine Compartment Start Button is stuck
24A x Engine Compartment Stop Button is stuck
14D x Engine overspeed protection
14E x x x x TurboCompound monitoring
Fuel metering CR Systems
151 x Rail pressure max.positive deviation exceeded
251 x Rail pressure positive deviation 2nd part
152 x Rail pr.max.pos.deviation exceeded conc.set flow of fuel
Maximum negative rail pressure deviation with metering unit on
153 x
lower limit is exceeded
154 x Minimum rail pressure exceeded
155 x Maximum rail pressure exceeded
156 x Rail pressure drop rate is higher than expected
157 x Setpoint of metering unit in overrun mode not plausible
Setpoint of fuel volume flow through metering unit is lower than
158 x
calculated limit
159 x x Metering unit PWM-powerstage
259 x Short circuit to battery of metering unit output
359 x Short circuit to ground of metering unit output
15A x x Metering unit AD-Channel
15B x High pressure test(deactivates rail pr.Monitor.)
15F x First collection fault path for potentially long term fault path
25F x Second collection fault path for potentially long term fault path
35F x Third collection fault path for potentially long term fault path
45F x Forth collection fault path for potentially long term fault path
55F x Fifth collection fault path for potentially long term fault path
Injectors 1
161 x x x x Cylinder1 - Short circuit Low/High
167 x x x x Cylinder1 - Open load
16A x x x x Cylinder4 - Open load
16B x x x x Cylinder5 - Open load
16C x x x x Cylinder6 - Open load
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
16D x Fault path to disable rail monitor. while compr.test active
16E x x x x The minimum number of injections was not reached --> stop the engine
16F x x x x Additive valve actuator
Injectors 2
171 x x x x Bank 1 specific errors - Short circuit / not classifyable
172 x x x x Bank 1 specific warnings - Open load
173 x x x x Bank 2 specific errors - Short circuit / not classifyable
174 x x x x Bank 2 specific warnings - Open load
175 x Misfire Cylinder 1
275 x x leakage or misfiring in cylinder 1
17A x Misfire Cylinder 6
27A x x leakage or misfiring in cylinder 6
17B x Misfire in multiple cylinders
17C x x x x Chip-specific errors-->stop engine
27C x x x x Chip-specific errors-->stop engine
17D x Common fault in combustion monitoring
17E x x x x Fault path of injection limitation
Air inlet system / EGR
181 x x Induction exhaust differential pressure
184 x Messages SRA2EDC
187 x AirCtl permanent positive governor deviaton
287 x AirCtl permanent positive governor deviaton
188 x AirCtl permanent negative governor deviaton
288 x AirCtl permanent negative governor deviaton
189 x Short circuit to Batt. for EGR power stage
289 x Short circuit to ground for EGR power stage
389 x x No load/excessive temp. for EGR power stage
18A x x x Power stage for EGR Bypass valve actuator
28A x x x Intercooler Bypass Valve Powerstage
18B x SC to BATT for throttle valve actuator powerst.
28B x SC to GND for throttle valve actuator powerst.
38B x x No load and excess temp. for TVA powerst.
18F x x x x Monitoring of Lambdasensor 1 Heater powerstage
Boost system and turbine speed
790 x Monitoring of the controller
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
191 x x x Boost pressure actuator current AD-channel
192 x Short circuit to Battery for BPA powerstage
292 x Short circuit to Ground for BPA powerstage
392 x x No load/excessive temp.for BPA power stage
193 x x x x Turbine speed
293 x x x x Actual turbo speed evaluation for interface
194 x Multi signal defects in EPCtl
195 x x x P2 pressure errors in EPCtl
196 x P3 pressure errors in EPCtl
197 x x x Turbine speed errors in EPCtl
198 x Multi signal defects in PCR
199 x x x P2 pressure errors in PCR
19A x x Turbine speed errors in PCR
19B x High turbine speed and high air pressure
19C x x P3 pressure errors in PCR
19D x Indicates torque limitation due to performance limiter
29D x Torque limitation due to NTC
39D x Performance limit active due to either stage
49D x Indicates torque limitation due to particulate filter
59D x Indicates torque limitation due to SCR
19E x Indicates torque limitation due to smoke limitation
29E x Indicates torque limitation due to turbo compound
39E x Indicates torque limitation due to turbo charger protection
49E x Indicates the torque limitation due to engine protection
59E x Indicates torque limitation due to noise control
69E x Indicates torque limitation due to Fuel quantity Limitation
19F x Multi signal defects in EGSys_NOxEstIv
Exhaust system (Aftertreatment)
1A1 x x x Lambda linear signal of Nox Sensor
2A1 x x x Lambda binary signal of Nox Sensor
1A2 x x x x Nox signal of Nox Sensor
2A2 x x x x NOx Sensor drift test
3A2 x x x x Nox Sensor plausibility test
1A3 x x x Heater of Nox Sensor
1A4 x Message Nox Sensor timeout
1A5 x Message DM1DCU timeout
1A6 x Message SCR1 timeout
2A6 x Message SCR2 timeout
1A7 x x x x Urea level error path
2A7 x SCR2 message: low urea level
3A7 x Not plausible CAN value of urea sensing
4A7 x Timeout for urea sensor
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
1A8 Error / Protection request on urea valve via SCR1
1AA x Not plausible CAN value of urea status
2AA x x x x Urea conductivity error path
3AA x x x x Urea concentration error path
1AB x x Exhaust gas temperature sensor before turbine
2AB x Exhaust Gas Pipe pressure sensor
1AC x x x x Heater used in EGR Mass Flow rate
2AC x CAN message EngGsFlowRt
1AD x x x x Recirculated Engine Exhaust Gas Temp. sensor
1AE x x Air humidity sensor
1AF x DM1DCU SPN1 message
Interfaces 1 (CAN-Bus)
1B1 x Busoff in CAN A
1B2 x Busoff in CAN B
1B3 x Busoff in CAN C
1B4 x Timeout for BC2EDC1
2B4 x Timeout for BC2EDC2
1B5 x Timeout for VM2EDC
1B6 x Timeout of CAN message WSI
1B7 x Timeout in CAN send messages
1B8 x Physical unplausibility of TSC-demand
1B9 x MIL visualization for BC2EDC1
1BA x Message Dashboard Display timeout
1BB x Message ERC1DR timeout
1BC x Message RxAMCONlv timeout
1BD x Timeout error of RxCCVS message
1BE x Physical plausibility DCS
1BF x CAN message RxEngTemp2
Interfaces 2 (CAN messages timeout)
1C1 x Timeout of CAN message EBC1
1C2 x Timeout of CAN message ETC1
1C3 x Timeout of CAN message TCO1
2C2 x Timeout of CAN message ETC2
1C4 x Timeout of CAN message TSC1-AE active
2C4 x Timeout of CAN message TSC1-AR active
3C4 x Timeout of CAN message TSC1-AE passive
4C4 x Timeout of CAN message TSC1-AR passive
1C5 x Timeout of CAN message TSC1-DE active
2C5 x Timeout of CAN message TSC1-DR active
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
3C5 x Timeout of CAN message TSC1-DE passive
4C5 x Timeout of CAN message TSC1-DR passive
1C6 x Timeout of CAN message TSC1-PE active
2C6 x Timeout of CAN message TSC1-PE passive
1C7 x Timeout of CAN message TSC1-TE active
2C7 x Timeout of CAN message TSC1-TR active
3C7 x Timeout of CAN message TSC1-TE passive
4C7 x Timeout of CAN message TSC1-TR passive
1C8 x Timeout of CAN message TSC1-VE active
2C8 x Timeout of CAN message TSC1-VR active
3C8 x Timeout of CAN message TSC1-VE passive
4C8 x Timeout of CAN message TSC1-VR passive
1C9 x Timeout of CAN message TF
2C9 x Timeout for message TimeDate
3C9 x Timeout for message HRVD (high resol.vehicle distance)
ECU 1 (internal checks)
1D1 x Communication error of CJ940
1D2 x x x Error state of EEPROM
1D3 x Recovery which is locked
2D3 x Recovery which is suppressed
2D4 x Recovery which is visible
1D4 x Communic.supervision Watchdog/Contr.-Flag
1D5 x x x Redundant shutoff paths during initial.
1D6 x Deviation between TPU and system time
1D7 x x Dataset variant coding
1D8 x Supervision of SPI-handler Flag
1D9 x x x x Error status ADC monitoring
Fault FMTC_trq2qBas_MAP containes non strictly monotonous q
1DA x
curves
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
Short circuit to Batt or Ground, no load, excess.temp. for high side
1E1 x x
power stage
Short circuit to Batt or Ground, no load, excess.temp. for low side
2E1 x x x
power stage
1E2 x Error state of Immobilizer (no fuel release)
1E3 x Energising time exceeds limit of overrun monitor.
1E4 x Plausibility error in engine speed check
1E5 x x 12V sensor supply voltage
1E6 x x Sensor supply voltage 1
1E9 x Supply voltage CJ940 upper limit
1EA x Supply voltage CJ940 lower limit
C87 ENT M38.10
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
1EB x x x Atmospheric Pressure Sensor
1EC x Runuptest is set to disable misfire detection during runup test
1ED x Fault path for Runup test
1EF x Mass of soot in oil beyond prescribed limit
Particulate trap
7F0 x Too long time spent in transition mode RgnNrm
1F1 x x Part.filter differential pressure sensor
1F2 x x Flow resistance monitoring
2F2 x Part.filter differential press.sensor not plaus.
1F3 x x x Differential pressure signal
2F3 x Dynamics of differential press.signal not plaus.
3F3 x Hose line defect so signal not plausible
4F3 x Pressure sensor blocked so signal not plaus.
1F4 x Pressure sensor frozen so signal not plausible
1F5 x Differential pressure above limit
1F6 x x Exhaust gas temp.sensor bef. oxidation catalyst
2F6 x Monitor.temp. upstream of Oxid.Catalyst
Temp.difference upstream from Oxidation catalyst of bank1 and 2
3F6 x
exceeded threshold
4F6 x Monitor.temperature upstream of Turbo charger
1F7 x x Part.filter pre temperature sensor
2F7 x Monitor.temp. upstream of Particul.filtre
Temp.difference upstream from Particulate filtre of bank1 and 2
3F7 x
exceeded threshold
1F8 x x x First exhaust gas temperature monitoring
2F8 x General temperature not plausible
3F8 x x x Second exhaust gas temperature monitoring
1F9 x Too high regeneration demand
1FA x Number of locked regenerations
2FA x Permanent regeneration
3FA x Regeneration demand number 2
4FA x Regeneration demand number 3
1FB x Error path of oxidation catalyst not present
1FC x Defect ratio between threshold limits
1FD x x Temperature of Outer control loop
2FD x x Temperature of Inner control loop
1FE x Mass of fuel in oil beyond warning limit
1FF x Mass of fuel in oil beyond action limit
2FF x Error check of critical time for oil dilution
C87 ENT M38.10
OCTOBER 2010 MAINTENANCE C87 ENT M62.10 5.77
SECTION 5
MAINTENANCE
Page
PERIODICITY OF CHECKS
AND MAINTENANCE OPERATIONS . . . . . . . 79
PREPARING THE ENGINE

FOR LONG IDLE PERIODS . . . . . . . . . . . . . . . . 81
ENGINE'S FIRST START/RESTORING

NORMAL OPERATING CONDITIONS . . . . . . 81
C87 ENT M38.10
5.78 C87 ENT M62.10 MAINTENANCE OCTOBER 2010

C87 ENT M38.10
o
PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS
Execution of the operations indicated below requires competence and compliance with the safety regulations enforced in
various Countries.
Checks can be performed by the user of the vessel and/or by workshop personnel.
Periodic maintenance operations must be performed by qualified personnel and require the use of tools, work instruments,
and suitable protection means.
Extraordinary maintenance operations must be performed by FPT authorized workshop personnel with adequate training and
sufficient technical information.
Checks Periodicity
Check engine lubricating oil level Daily
Check engine coolant level Daily
Check oil level in the gearbox Daily
Inspect exhaust duct(s) Daily
Drain water from fuel pre-filter(s) (1) 150 hours
Check battery terminal tightening and cleanliness Half-yearly
Check electrolyte level in batteries (1) Half-yearly
Check condition of oil vapor filter with clogging indicator (with the engine 300 hours
running)
Periodic maintenance operations Periodicity

Clean air filter(s) (1) 300 hours
Check belt tension and conditions 300 hours
Check zinc anode corrosion condition (4) yearly
Restore battery electrolyte level Half-yearly
Drain/draw water and condensations from tank(s) (1) 300 hours
Replace engine lubricating oil (2) 300 / 600 hours
Replace oil vapor filter (8) 600 hours
Replace fuel pre-filter(s) (1) (3) 600 hours (Max)
Replace fuel filter(s) (1) (3) 600 hours (Max)
Replace oil filter(s) (2) 300 / 600 hours
Replace gearbox(es) oil (see data provided by the manufacturer)
Check seal of one-way valve in pre-lubrication system (as required) 600 hours
Clean turbocompressor 900 hours or 2 years
Inspect sea water intake (1) yearly
Check wear of sea water pump impeller 900 hours
Adjust valve-rocker arm clearance 1200 hours
Extraordinary maintenance operations (5) Periodicity

Clean heat exchangers (6) 1200 hours or 2 years
Check pre-post heating system operating condition (as required) 1200 hours or 3 years
Replace water pump and alternator drive belt 1200 hours or 3 years
CAUTION
Oil filter and oil change schedules are different for the two applications:
C87 ENT M38.10 : Every 600 hours
C87 ENT M62.10 : Every 300 hours
C87 ENT M38.10
(1) The periodicity of these operations may vary depending on

engine use and environmental conditions of operation.
(2) These operations must be conducted annually even if the
specified number of operating hours is not reached.
(3) Maximum time interval for high quality fuel; This may be
reduced depending on contamination. The filter is provided
with a clogging sensor; if a clogging indication occurs, replace
the filter. The pre-filter is provided with a water presence
detector; if the presence of water is detected, drain the water
from the appropriate drain and if the light stays lighted,
replace the filter.
(4) If zinc corrosion exceeds 50% of its volume, replace it.
(5) Instructions provided in Section 6.
(6) Combustion air/sea water exchanger: clean air side and
water side. Engine coolant/sea water exchanger: clean the
sea water side. Gearbox oil/sea water exchanger (if
provided): clean sea water side.
(7) These operations must be performed every three years even
if the specified operating hours are not reached.
(8) On every engine oil replacement.
C87 ENT M38.10
PREPARING THE ENGINE ENGINE'S FIRST START/RESTORING

FOR LONG IDLE PERIODS NORMAL OPERATING CONDITIONS
To prevent oxidation of the internal parts of the engine and 1. Drain the residual protective oil type 30/M from the
of some components of the injection system, if idle periods sump;
exceeding two months are expected, the engine needs to be
2. Pour lubricating oil into the engine, as provided by the
prepared, with six-months periodicity, proceeding as follows:
specifications and in the quantities set out in the Table of
1. Drain the lubricating oil from the sump, after heating the Refills;
engine;
3. Drain the CFB protective liquid from the fuel line, com
2. Pour 30/M protective oil (alternatively, oil conforming pleting the operations set out in item 3. of PREPARING
with MIL 2160B Type 2 specifications) into the engine to THE ENGINE FOR LONG IDLE PERIODS;
the minimum level marked on the dipstick. Start the
4. Remove the caps and/or the seals from the engine's
engine and let it run for about 5 minutes;
intake, exhaust, aeration and vent ports, restoring normal
3. Drain the fuel from the injection line, from the filter and operating conditions. Connect the turbocompressor
from the ducts in the cylinder heads. To do so, loosen the intake to the air filter;
drain cap in the front part of the cylinder head and the
5. Attach the fuel lines to the vessel's fuel tank, completing
fuel inlet junction with the cylinder head, taking care to
the operations set out in item 4. of PREPARING THE
prevent the fuel from coming in contact with the
ENGINE FOR LONG IDLE PERIODS.
auxiliaries belt;
During the filling operations, attach the fuel tank return
4. Connect the fuel line to a tank containing CFB protective pipe to a collecting container to prevent residues of CFB
liquid (ISO 4113) and assist the inflow of the liquid by protective liquid from flowing into the vessel's fuel tank;
pressurizing the line and turning the engine over for
6. Verifiy the quantity of cooling liquid and refill as provided
about 2 minutes, after excluding the operation of the
by the specifications;
injection system. The required operation may be carried
out by directly polarizing the terminal 50 of the electric 7. In order to enable the sea water pump priming it is
starter motor with positive voltage 24 V, using a necessary to input water into the forcing circuit.
conductor prepared for the occasion; Remove the sacrifical anode (1 of Figure 1), introduce 1.5
litres of water into the hole; reassemble the anode and
5. Nebulize 30/M protective oil at the rate of about 87 g (10
tighten it as required.
g per liter of displacement) into the two
WARNING
turbocompressors intake, while the engine is turning
If the engine is activated after a long time, it is necessary
over as described above;
to repeat the operations mentioned in item 7.
6. Close with suitable stoppers or seal with adhesive tape
8. Start the engine and keep it running until idling speed has
all engine intake, exhaust, aeration and venting ports;
completely stabilized;
7. Drain the residual 30/M protective oil from the sump; it
9. Shut the engine down and delete the errors which may
may be re-used for 2 more engine preparation perations;
have been stored in the injection system ECU during the
8. Apply tags with the inscription ENGINE WITHOUT operation stabilization phases. For reset operation, see
OIL on the engine and onboard panel; Blink code paragraph in Section 4;
9. Drain the coolant, if it has not been mixed with antifreeze 10. Remove the tags with the inscription ENGINE
and corrosion inhibiting agents, affixing tags to indicate WITHOUT OIL from the engine and from the panel.
that the operation has been carried out.
If external parts of the engine are to be protected, spray
protective liquid OVER 19 AR onto unpainted metal parts,
such as flywheel, pulleys and others; avoid spraying belts,
connector cables and electrical equipment. Figure 1
147001
C87 ENT M38.10

C87 ENT M38.10
OCTOBER 2010 SERVICING OPERATIONS ON INSTALLED ENGINE C87 ENT M62.10 6.83
SECTION 6
SERVICING OPERATIONS ON INSTALLED

ENGINE
Page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . 85
PRESCRIPTIONS FOR WORK ON THE

INJECTION SYSTEM AND ITS COMPONENTS 86
REPLACING BELT . . . . . . . . . . . . . . . . . . . . . 87
REPLACING THE ELECTRO-INJECTORS . . . 87
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Intake and exhaust rocker arm clearance

adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Engine lubricant replacement . . . . . . . . . . . . . 88
Air filter/s replacement . . . . . . . . . . . . . . . . . . 89
Fuel filter/s replacement . . . . . . . . . . . . . . . . . 89
Oil filter replacement . . . . . . . . . . . . . . . . . . . 89
Filter support with exclusion levers . . . . . . . . 90
MARINISATION OVERHAUL . . . . . . . . . . . . 91
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
CLEANING THE AIR/SEA WATER HEAT

EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . 93
CLEANING THE ENGINE COOLANT/SEA

WATER HEAT EXCHANGER . . . . . . . . . . . . 94
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
INSTRUCTIONS FOR DISEMBARKING

THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 97
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
C87 ENT M38.10
6.84 C87 ENT M62.10 SERVICING OPERATIONS ON INSTALLED ENGINE OCTOBER 2010

C87 ENT M38.10
FOREWORD
Many of the procedures for carrying out the instructions that

follow depend on the con.tion of the housing on the vessel
and on the configuration of the installation components.
Prescriptions and cautions for use, handling and technical
assistance are provided in Section 9.
Technicians and maintenance personnel are reminded of the
need to comply with safety rules.
The checks necessary at the completion of an installation or
re-embarkation are described in the C13 ENT M38.10 -
C13 ENT M62.10 Installation Directive document.
Spare parts will be supplied only if the following data are
provided:
- Engine technical code and serial number;
- Part number as per spare parts catalog.
The information provided below refers to engine
characteristics that were current as of the publishing data.
The manufacturer reserves the right to make changes at any
time and without advance notice, to comply with technical
or commercial requirements or to adapt to legal
requirements in different Countries.
The manufacturer shall not be liable for any errors and
omissions.
The FPT Technical Assistance Network is always at the
Customer's side with its competence and professionalism.
C87 ENT M38.10
PRESCRIPTIONS FOR WORK ON THE INJECTION SYSTEM AND ITS COMPONENTS
The successful outcome of repair work is assured by the To proceed with the overhaul of the engine or its parts, you
operator's experience and ability and by compliance with the must disconnect the electrical connections of the injection
following instructions. system's components and of the sensors providing
indications on the control panel.
Before performing work involving components of the injec
tion system, take note of the content of the ECU fault mem To proceed as indicated, we provide below the procedure to
ory with the appropriate FPT diagnosis equipment, writing avoid the risk that the ECU of the injection system may detect
the results down or printing them. and store errors or system faults.
- Replacement of the ECU EDC 7 must be authorized by - Set the key switch to the STOP position;
FPT after specific agreements with the Technical
- Wait 10 sec. and disconnect the battery terminals;
Assistance Service;
- Disconnect the connections according to the
- The electro-injectors cannot be overhauled; their
prescriptions set out in Section 3;
replacement must be authorized by FPT with the specific
agreement of the Technical Assistance Service; for - Remove, if necessary, the entire wiring harness from the
disassembly, follow the indications provided in the retaining bracket;
specific paragraph of this Section;
- Remove, if necessary, the complete electronic unit after
- Keep parts and components clean, making sure that disconnecting the multipolar connectors.
during handling and assembly (starting with the simple
replacement of filter and pre-filter) no sludge or foreign
matter is allowed to enter the lines, with particular
attention to the fuel supply line in the segment
downstream of the filter;
- Maintain the proper polarization of all electrical
connections;
- Tighten the threaded connections to the prescribed
torque;
- Ensure that the flywheel and camshaft sensors are
positioned so they abut, ensuring they are as close to
perpendicular as possible with the bearing surface.
CAUTION
- Do not disconnect electrical connections without
removing power from the circuits first;
- Do not proceed with operating simulations with
unsuitable tools and instruments;
- Do not force measuring probes or mechanical tools
into the electrical connections;
- Do not proceed with arc welding without first
disconnecting electronic system units.
C87 ENT M38.10
REPLACING BELT
Figure 1 Figure 3
114024
- Unlock rocker arm shaft retaining screws (4).

- Disconnect fuel pipelines (1) from injector rail, fuel
supply line (2) of high pressure pump to rail and return
line (3).
05_070_C
- With the tool (1) loosen the tensioning device acting in Figure 4
the direction indicated by the arrow. Extract the auxiliary
organ drive belt (2), insert the new belt verifying that it
is correctly set onto the pulleys. Release the tensioning
device. The automatic tensioning device requires no
further adjustment.
REPLACING THE ELECTRO-INJECTORS
Removal
Figure 2
114025
Apply tool 99360558 (1) to rocker arm shaft and remove

shaft, remove crosspieces (3) from cylinder head.
Figure 5
114016
Unlock retaining screws (2) and remove head cover (1) to

reach injector and rail wiring.
147002
Remove retaining brackets (1) and remove injectors (2).

C87 ENT M38.10
Intake and exhaust rocker arm clearance Engine lubricant replacement

adjustment Proceed only with engine not running and at low
Figure 6 temperature to avoid any risk of burns.
Figure 7
114287
Adjustment of clearance between rocker arms and

intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted;
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5
and 3-4. 147003
In order to perform these operations correctly, refer to

The above operations can be performed by acting on the
procedure and table below.
push button located on the electronic module. Fore safety
- Use a polygonal spanner to release lock nut (1) of rocker reasons controls enabled on only when the key switch is
arm adjustment screw (2). turned to 8A (stop).
- Insert filler gage (3) having same value of operating - Place under the cock (1) a container to collect the
clearance shown in Characteristic and data tables. exhaust oil.
- Use special spanner to lock/unlock adjustment screw. - Open the cock and press (A) towards DISCHARGE,
- Check that filler gage (3) slides with a low friction. until it is fully empty.
- Lock nut (1) retaining the adjustment screw.
Figure 8
IGNITION ORDER 1-4-2-6-3-5
START AND BALANCE ADJUST

ROTATION VALVES OF CLEARANCE
CLOCKWISE CYLINDER No. OF VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2 147004
120 1 6
120 4 3 - Connect the cock to the new oil container and press
120 2 5 the button towards CHARGE until filling is completed.
- Close again the charge/discharge tap and check - using
ATTENTION the oil dipstick - that the oil level in the oil sump is
between the range MIN e MAX.
In order to correctly carry out adjustments above, it is
mandatory to perform the sequence indicated in the table, - Dispose oil observing current regulations in force.
checking exact positioning at each phase by means of pin
99360612.
C87 ENT M38.10
Air filter/s replacement Oil filter replacement

- Remove the collar (1) shown in picture then remove the Use only filters with filtering degree equal to the above ones
filter. (see FREQUENCY).
- Replace. With traditional filter support
- Restore regular operating conditions after having placed Proceed only with engine not running and at low
the filter in its housing. temperature to avoid any risk of burns, after emptying
exhaust oil.
Figure 9
Figure 11
147005
Fuel filter/s replacement

Proceed only with engine not running and at low
temperature to avoid any risk of burns.
Use only filters with filtering degree equal to the above ones
(see FREQUENCY). 147007
Figure 10
- Place under the cock a container to collect the exhaust
oil.
- Remove filters.
- Accurately clean surfaces.
- Moist seals of the new filters with some oil.
- Manaully tighten until contact is made, then tighten
again for 3/4 of turn.
- Dispose drained liquids observing current regulations
in force.
147006
- Remove filter (1) by unscrewing it.

- Moist seals of the new filters with diesel or engine oil.
- Manually tighten until contact is made, then tighten again
for 3/4 of turn.
ATTENTION
- Loosen the bleeding connection on the filter support
and act on the hand pump of the pre-filter until fuel flows Proceed with utmost care, considering the fluid high
out without air. temperature and the presence of moving parts. Always
- Tighten the connection and start the engine acting on wear suitable personal protection equipped.
the pump, also during the first startup phases.
C87 ENT M38.10
Filter support with exclusion levers

The support with exclusion lever allows replacing the filter
also with running engine.
Under normal conditions, the selector (1) lever should be on
the left. Only in the event of replacement should it first be
positioned in the centre then on the right to allow the small
(emergency) filter to operate
Figure 12
147008
- Place under the cock a container to collect the exhaust oil.

- Remove filters.
- Accurately clean surfaces.
- Moist seals of the new filters with some oil.
- Manaully tighten until contact is made, then tighten again
for 3/4 of turn.
- Dispose drained liquids observing current regulations in
force.
Put the lever back into its original position (left).
ATTENTION
Proceed with utmost care, considering the fluid high
temperature and the presence of moving parts. Always
wear suitable personal protection equipped.
ATTENTION
Do not exclude both filters at the same time to avoid any
damage.
C87 ENT M38.10
MARINISATION OVERHAUL Figure 16

Removal
Figure 13
143687
Remove the air filter (4), the turbocharger (1), the pipe (2)
143684 and the fuel pipes (3).
Remove the oil filter mount (1) and the oil dipstick (2).
Figure 17
Figure 14
143688
143685 Disconnect the exhaust stub pipe (1), the fuel filter (2) and
the intake duct (3).
Remove the engine mountings (1), the oil drain pump (2) and
the sea water exhaust pipe (3).
Figure 18
Figure 15
143689
143686
Disconnect the oil inlet pipe from the inverter (1) and the oil
Remove the electronic control unit (1), the stack exhaust (2) outlet pipe to the inverter. (2).
(if present) and the combusted gas/sea water exhaust (3).
C87 ENT M38.10
Figure 19 Figure 21
1436922
143690
Remove the air/water exchanger (1) and the water/water

Remove the sea water pump (1) and the inverter oil heat heat exchanger (2)
exchanger (2)
Figure 20 Figure 22
143691
143693
Disconnect the coolant temperature sensor (2), the
thermostat (1) and the coolant inlet pipe to the engine water Remove the combusted gas/sea water cooled exhaust
pump (3) manifold (1)
C87 ENT M38.10
CLEANING THE AIR/SEA WATER HEAT EXCHANGER
Figure 23
143699
1.Body - 2. Tube bundle - 3. Sealing rings - 4. Zinc sacrificial anode - 5. Tube bundle fixing screw -
6. Cover - 7. Spacer.
In order to guarantee a perfect operation of the heat

exchanger, regularly clean the tube bundle. If the surfaces of
the heat exchanger come into contact with salted water, they
may be subjected to biological fouling and to hydrocarbon
deposits which may be present in harbors' waters; surfaces
coming into contact with combusting air are subject to oil
deposits resulting from the fumes exhausted at the base and
sucked downstream of the air filter.
- Remove tube bundle fixing plugs and screws (5);
- Remove the tube bundle (2) from the exchanger body
and immerse it for a few minutes in a solution prepared
with water and a degreasing scale-remover detergent,
observing the detergent manufacturer's directions for
use. The cleansing solution should not damage copper,
brass, aluminum and tin;
- Complete tube cleaning by rinsing thoroughly with fresh
water, until detergent residuals are entirely removed;
- Reassemble the tube bundle (2) by correctly positioning
spacers (7), sealing rings (3) and covers (6);
- Reassemble screws (5) in order to suitably secure the
tube bundle and relevant plugs;
- Check the zinc anode corrosion level (4); replace the
anode if corrosion exceeds 50% of the volume.
C87 ENT M38.10
CLEANING THE ENGINE COOLANT/SEA WATER HEAT EXCHANGER

Figure 24
143770
1. Tube bundle - 2. Body - 3. Sealing rings - 4. Cover - 5. Tube bundle fixing screw - 6. Spacer - 7. Zinc sacrificial anode
In order to guarantee a perfect operation of the heat

exchanger, regularly clean the tube bundle. If the surfaces of
the heat exchanger come into contact with salted water, they
may be subjected to biological fouling and to hydrocarbon
deposits which may be present in harbors' waters.
- Remove the tube bundle (1) from the exchanger body
and immerse it for a few minutes in a solution prepared
with water and a degreasing scale-remover detergent,
observing the detergent manufacturer's directions for
use. The cleansing solution should not damage copper,
brass, aluminum and tin;
- Complete tube cleaning by rinsing thoroughly with fresh
water, until detergent residuals are entirely removed;
- Reassemble the tube bundle (1) by correctly positioning
spacer (6), sealing rings (3) and covers (4);
- Check the zinc anode corrosion level (7); replace the
anode if corrosion exceeds 50% of the volume.
C87 ENT M38.10
Fitting Figure 28
Figure 25
143690
143693 Fit the inverter oil heat exchanger (2) and the sea water
pump (1).
Fit the combusted gas/sea water cooled exhaust manifold (1).
Figure 29
Figure 26
143689
143692 Connect the inverter oil inlet (1) and outlet (2) pipes.
Fit the air/water exchanger (1) and the water/water heat
exchanger (2).
Figure 30
Figure 27
143688
143691
Fit the exhaust stub pipe (1), the fuel filter (2) and the intake
Reattach the coolant inlet pipe to the engine water pump (3), duct (3).
the thermostatic valve (1) and the coolant sensor (2).
C87 ENT M38.10
Figure 31 Figure 33
143687 143685
Connect the pipe (2), the turbocharger (1), the air filter (4) Fit the engine oil drain pump (2), the sea water exhaust pipe
and reattach the fuel pipes (3). (3) and the engine oil mounts (1).
Figure 32 Figure 34
143686
143684
Fit the combusted gas/sea water exhaust (3), the stack Fit the oil filter mount (1) and the oil dipstick (2).
exhaust (2) (if present) and the electronic control unit (1).
C87 ENT M38.10
INSTRUCTIONS FOR DISEMBARKING THE ENGINE
The following is a description of the recommended sequence

of operations to be completed before extracting the engine
from the vessel.
- After the key switch has been in the OFF position for at
least 10 seconds, disconnect the battery terminals and
disconnect the connectors from the relay box;
- Disconnect from the engine the power wiring harness
terminals (battery positive and negative);
- Loosen and remove the fuel pipelines and the pipes of
the gearbox heat exchanger, if provided;
- Loosen and remove the sea water inlet pipes, engine
exhaust pipes, and, if separate, the sea water loop
discharge;
- Remove the pipeline from the engine coolant expansion
vessel;
- Loosen and remove engine anchor bolts;
- Uncouple the gearbox;
- Hitch the engine following the prescriptions provided
below.
Handling
The engine must be handled by experienced personnel, using
the prescribed tool or a rocker arm that keeps the lifting lines
parallel and with adequate equipment in terms of capacity
and size.
The two eyebolts (provided exclusively for lifting the engine)
must always be used simultaneously.
C87 ENT M38.10

C87 ENT M38.10
OCTOBER 2010 TOOLS C87 ENT M62.10 7.99
SECTION 7
TOOLS
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
7.100 C87 ENT M38.10 TOOLS OCTOBER 2010
C87 ENT M62.10

C87 ENT M38.10
TOOLS
Tool No. Description
Rotary telescopic stand (range 2000 daN, torque 375 daNm)

99322230
PT - Plus
99327210
PT - Box
99327281
Adaptors for 38 to 30 pin connectors

99331043 (component of 99368554)
99340051 Extractor for crankshaft front gasket
99340054 Extractor for crankshaft rear gasket

C87 ENT M62.10
TOOLS
99342149 Extractor for injector-holder
99346245 Tool to install the crankshaft front gasket
99346260 Percussion extractor
Pliers for assembling and disassembling piston split rings

99360184 (105-106 mm)
99360264 Universal extractor internal components
99360288 Box wrench for block junction bolts to the underblock

C87 ENT M38.10
TOOLS
99360292 Box wrench for block junction bolts to the underblock
99360294 Tool to fit back valve guide (to be used with 99360288)
Compression tool for checking the protrusion of cylinder liners

99360334
Cylinder liner compression plate

99360335 (to be used with 99360334)
Cylinder liner compression plate

99360341
99360500 Tool to lift crankshaft

C87 ENT M62.10
TOOLS
99360505 Tool to lift crankshaft
99360558 Percussion extractor
99360585 Swing hoist for engine disassembly assembly
Belt to insert piston in cylinder liner (60 - 125 mm)

99360605
99360612 Tool for positioning engine P.M.S.
99360613 Tool for timing of phonic wheel on timing gear

C87 ENT M38.10
TOOLS
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners (to be used with specific rings)
99360724 Ring (115 mm) (to be used with 99360706)
Tool to take down-fit engine valves

99361042 (to be used with special plates)
99365054 Tool for injector holder heading

C87 ENT M62.10
TOOLS

99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
99389833 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
Torque screwdriver for calibrating the injector solenoid valve

99389834 connector check nut
99390310 Valve guide sleeker
99390772 Tool for removing injector holding case deposits

C87 ENT M38.10
TOOLS
99390804 Tool for threading injector holding cases to be extracted
Reamer to rectify injector holder lower side

99394043 (to be used with 99394014)

99394044 (to be used with 99394045)

99394045 (to be used with 99394043 and 99394044)
Measuring pair for angular tightening with 1/2

99395216 and 3/4 square couplings

C87 ENT M62.10
TOOLS
Plate for take down-fit engine valves

99395222 (to be used with 99360261)
99395223 Tool to remove oil filter (engine)
99395603 Dial gauge (0 - 5 mm)

C87 ENT M38.10
OCTOBER 2010 OVERHAUL C87 ENT M62.10 8.109
SECTION 8
OVERHAUL
Page
Graph and symbols . . . . . . . . . . . . . . . . . . . . 111
GENERAL CHARACTERISTICS . . . . . . . . . . . . 112
ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 113
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 119
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 132
Checks and measurements .............. 132
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . 133
Replacing cylinder liners . . . . . . . . . . . . . . . . . 134
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Fitting and checking protrusion . . . . . . . . . . . 134
CRANKSHAFT ......................... 135
Measuring main journals and crank pins . . . . . 136
PRELIMINARYMEASUREMENT OF MAIN AND BIG

END BEARING SHELL SELECTION DATA . . 137
Selecting the main and big end bearing shells . 138
Replacing the timing control gear and the

oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
(cont)
C87 ENT M38.10
8.110 C87 ENT M62.10 OVERHAUL OCTOBER 2010
Page Page
PISTON CONNECTING ROD ASSEMBLY . . 146 BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Use beater 99360505 to change bushings . . . 162
CONNECTING ROD . . . . . . . . . . . . . . . . . . 149 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . 162
Version C87 ENT M38.10 . . . . . . . . . . . . . . . 150 Fitting the valves and oil seal ring . . . . . . . . . . 162
Version C87 ENT M62.10 . . . . . . . . . . . . . . . 151 ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . 163
Mounting the connecting rod - piston Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Rockers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Mounting the piston rings . . . . . . . . . . . . . . . . 152
LUBRICATION CIRCUIT COMPONENTS . . 164
Fitting connecting rod - piston assemblies in
the cylinder liners . . . . . . . . . . . . . . . . . . . . . . 153 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Checking piston protrusion . . . . . . . . . . . . . . 153 Overpressure valve . . . . . . . . . . . . . . . . . . . . 164
Checking assembly clearance of big end pins . 154 Engine oil filter adapter . . . . . . . . . . . . . . . . . . 165
CYLINDER HEAD .................... 154 Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . 165
Valve removal ........................ 154 Oil pressure control valve . . . . . . . . . . . . . . . . 166
Checking the planarity of the head on the Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 166

cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 154
COMPONENTS OF THE COOLING SYSTEM 167
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Removing deposits and checking the valves . . 155
Thermostatic valve . . . . . . . . . . . . . . . . . . . . . 167
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . 155
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Replacing of valve guides . . . . . . . . . . . . . . . . 156
High pressure pump installation . . . . . . . . . . . 172
REPLACING INJECTOR HOLDER CASES . . 156
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . 172
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Engine flywheel installation . . . . . . . . . . . . . . . 172
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Camshaft installation . . . . . . . . . . . . . . . . . . . . 173
Checking protrusion of injectors . . . . . . . . . . 158
TIMING CAMSHAFT AND FLYWHEEL
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . 159 USING TOOL 99395223 . . . . . . . . . . . . . . . . 174
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . 159 Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 174
Intermediate gear pin . . . . . . . . . . . . . . . . . . . 159 Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 176
Idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 TIMING CAMSHAFT AND FLYWHEEL

WITHOUT TOOL 99395223 . . . . . . . . . . . . 176
Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . . 159
Timing camshaft . . . . . . . . . . . . . . . . . . . . . . . 176
Replacing the bushings . . . . . . . . . . . . . . . . . . 159
Timing flywheel . . . . . . . . . . . . . . . . . . . . . . . . 179
Checking cam lift and pin alignment . . . . . . . 160
Intake and exhaust rocker arm clearance
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 161 adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
C87 ENT M38.10
Graph and symbols
Surface for machining

Machine finish
Interference
Strained assembly
Thickness
Clearance
Intake
Exhaust
Operation
Compression ratio
Preload
Oversized
Higher than ...
Maximum, peak
Undersized
Less than ...
Minimum
Selection
Classes
Oversizing
C87 ENT M38.10
GENERAL CHARACTERISTICS
C87 ENT M38.10

Engine
C87 ENT M62.10
mm
Cycle Diesel 4 strokes
Air feeding Turbocharged with aftercooler
Injection Direct
N. of cylinders 6 in line

Diameter mm 117
Stroke mm 135
+ + +.. = Total displacement cm3 8710
Compression ratio 16 : 1
A
Valve timing
opens before TDC A 17
closes after BDC B 31

B
opens before BDC D 48

closes after TDC C 9
D
For timing check
X mm 0.4 0.05
X
mm 0.6 0.05
C87 ENT M38.10
ASSEMBLY CLEARANCE DATA
C87 ENT M38.10

Engine
C87 ENT M62.10
Cylinder block and crank mechanism components mm

1
Cylinder sleeve bore
upper
130.500 to 130.525
1
lower
129.510 to 129.535
Cylinder liners:
outer diameter:
upper 130.461 to 130.486
L
2
lower 129.475 to 129.500
2 length L 226.15
Cylinder sleeve -
crankcase bore:
upper 0.014 to 0.064
lower 0.010 to 0.060
Outside diameter 2 -
Cylinder sleeve
3 inside diameter 3A* 117.000 to 117.012
X inside diameter 3B* 117.010 to 117.022
Protrusion X
* Available dia. class
Pistons:
measuring dimension X 15
outside diameter 1 A* 116.894 to 116.906
1 external diameter 1 B** 116.904 to 116.916
pin bore 2 52.010 to 52.016
X
* Class A pistons supplied as
2 spares.
** Class B pistons are fitted in
production only and are not
supplied as spares.
Piston - cylinder sleeve A* 0.094 to 0.118
* Available dia. class B* 0.094 to 0.118
Piston diameter 1 -
X
Pistons protrusion X 0.873 to 1.117
3 Gudgeon pin 3 51.994 to 52.000
Gudgeon pin - pin housing 0.010 to 0.022

C87 ENT M38.10
C87 ENT M38.10

Engine
C87 ENT M62.10
mm
X1 X1 3.120 to 3.140
X2 Piston ring grooves X2 2.550 to 2.570
X3 4.020 to 4.040
X3
Piston rings:
S1 trapezoidal seal S1 3.000
S2 lune seal S2 2.470 to 2.500
S3 milled scraper ring with slits
and internal spring S3 3.970 to 3.990
1 -
Piston rings - grooves 2 0.050 to 0.100
3 0.030 to 0.070
Piston rings -
X1 Piston ring end gap

in cylinder liners:
X2
X1 0.30 to 0.40
X3
X2 0.60 to 0.75
X3 0.35 to 0.65
Small end bush housing
1 1 55.700 to 55.730
Rated value 85.987 to 86.013
Big end bearing housing 2
1 85.987 to 85.996
2 Selection classes 2 2 85.997 to 86.005
3 86.006 to 86.013
Small end bush diameter
4 outside 4 55.780 to 55820
3 inside 3 52.015 to 52.030
Big end bearing shell S
Red
Green 1.994 to 2.002
S Yellow * 2.002 to 2.010
* Fitted in production only 2.010 to 2.018
and not supplied as spares
Small end bush - housing 0.05 to 0.08
Piston pin - bush 0.015 to 0.030
Big end bearing shells 0.127 - 0.254 - 0.508
C87 ENT M38.10 C87 ENT M62.10

Connecting rod weight
g g
A
3.450 to 3.470 3.308 to 3.338
Class B
3.471 to 3.490 3.339 to 3.368
C
3.491 to 3.510 3.369 to 3.398
C87 ENT M38.10
C87 ENT M38.10

Engine
C87 ENT M62.10
mm
Main journals 1 Rated value 92.970 to 93.000
1 92.970 to 92.979
Selection class 2 92.980 to 92.989
3 92.990 to 93.000
Crankpins 2 Rated value 81.915 to 81.945
1 2 1 81.915 to 81.924
3 81.935 to 81.945
Main bearing shells S1
Red 2.968 to 2.978
S1 S 2 Green 2.978 to 2.988
Yellow* 2.988 to 2.998
Big end bearing shells S2
Red 1.994 to 2.002
Green 2.002 to 2.010
Yellow* 2.010 to 2.018
* Fitted in production only
and not supplied as spares
Main bearing housings 3 Rated value 99.000 to 99.030
3 1 99.000 to 99.009
3 99.020 to 99.030
Bearing shells - main journals 0.050 to 0.090
Bearing shells - big ends 0.0540 to 0.080
Main bearing shells 0.127 - 2.254 - 0.508
Big end bearing shells 0.127 - 2.254 - 0.508
Main journal,
thrust bearing X1 39.96 to 40.04
X1
Main bearing housing,

thrust bearing X2 38.94 to 38.99
X2
X3 Thrust washer
halves X3 3.38 to 3.43
Driving shaft shoulder 0.10 to 0.30

C87 ENT M38.10
C87 ENT M38.10

Engine
C87 ENT M62.10
Cylinder heads - valve train mm
Valve guide housings

in cylinder head 1
12.980 to 12.997
2 8.023 to 8.038
Valve guide
3 13.012 to 13.025
3
Valve guides - housings

0.015 to 0.045
in the cylinder heads
Valve guide 0.2 - 0.4
4 Valves:
4 7.970 to 7.985
60 30' 7' 30"
4 7.970 to 7.985
45 30' 7' 30"

Valve stem and its guide 0.038 to 0.068
Housing in head
for valve seat:
1 41.985 to 42.020
1 1 40.985 to 41.020
Outside diameter of valve seat;

angle of valve seat
in cylinder head:
2 42,060 to 42,075
60 - 30
2 41.060 41.075
45 - 30'
X 0.5 to 0.8
Recessing
X of valve X
1.6 to 1.9
Between valve seat

and head 0.040 to 0.090
C87 ENT M38.10
C87 ENT M38.10

Engine
C87 ENT M62.10
mm
Valve outside spring

height:
free height H 70.77
H H1
H2 under a load of:
N 460 23 N H1 51
N 740 33 N H2 39
Injector protrusion X 1.2 to 1.5

X
Camshaft bush
housing fitted
in the cylinder head:
17 69.000 to 69.030
Camshaft journal
diameter:
17 64.924 to 64.080
1 3
Camshaft bushing
outer diameter 69.090 to 69.130
Camshaft bushing
inner diameter 65.080 to 65.116
Bushings and housings

in engine block 0.060 to 0.130
Bushings and journals

0.100 to 0.192
Cam lif
H 7.4034
8.2108
1
Rocker shaft 1 31.964 to 31.980
C87 ENT M38.10
C87 ENT M38.10

Engine
C87 ENT M62.10
mm
Bushing housing
in rocker arms:
32.025 to 32.041
32.025 to 32.041
Between bushings
and housings:
0.045 to 0.077
0.045 to 0.077
C87 ENT M38.10
TIGHTENING TORQUES
PART TORQUE
Nm kgm
Pipe union for piston cooling nozzle M12X1.5 35 2 3.5 0.2
Heat exchanger retaining screws 63 7 6.3 0.7
Plug 125 15 12.5 1.5
Spacer and oil sump fastening screws
M10 41.5 3.5 4.1 0.3
Gearcase fastening screws to cylinder block:
M10x1.25 41.5 3.5 4.1 0.3
M12x1.75 63 7 6.3 0.7
M8x1.25 23.5 1.5 2.3 1.5
Cylinder head fastening screw
First stage pre-tightening 50 5
Second stage pre-tightening 100 10
Third stage angle closing 90
Fourth stage angle closing 75
Rocker arm shaft fastening screw 104.5 10.5 10.4 1
Locknut for rocker arm adjusting screw 39 5 3.9 5
Electroinjector retaining bracket screws
M10 41 3 4.1 0.3
Shoulder plate fastening screws to head 23.5 3.5 2.3 0.3
Engine support bracket fastening screws to cylinder head 74 8 7.4 0.8
Gear fastening screws to camshaft M10x1,5x45
First stage pre-tightening 25 2.5
Second stage pre-tightening 45
Phonic wheel fastening screws to distribution gear 8.5 1.5 0.8 0.1
Exhaust pipe fastening screws
pre-tightening 32.5 7.5 3.2 0.7
tightening 47.5 2.5 4.7 0.2
Connecting rod cap fastening screws:
Engine flywheel fastening screws M18x1.5x72
Flywheel pulley fastening screws to crankshaft
Main journal retaining screws
Second stage pre-tightening 60 + 60
Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly
C87 ENT M38.10
PART TORQUE
Nm kgm
Damper flywheel fastening screws 115 15 11.5 1.5
Idler gear pin fastening screws M12x1,75x90
Second stage angle closing 90
Idle gear link rod fastening screw 24.5 2.5 2.4 0.2
Oil pump fastening screw 24.5 2.5 2.4 0.2
Oil pump suction rose fastening screw 24.5 2.5 2.4 0.2
Front cover fastening screw to cylinder block 19 3 1.9 0.3
Control unit fastening screw to cylinder block 19 3 1.9 0.3
Fuel filter support fastening screw to cylinder head M10x1,25x60 37 3 3.7 0.3
Screw securing the engine support to the wheelcase
Second stage angle closing 60
Turbo-compressor fastening screws and nuts
pre-tightening 32.5 7.5 3.2 0.7
tightening 46 2 4.6 0.2
Water pump fastening screw to cylinder block 24.5 2.5 2.4 0.2
Pulley fastening screw to hub 55 5 5.5 0.5
Rocker arm cover fastening screws 8.5 1.5 0.8 0.1
Thermostat box fastening screws to cylinder head 24.5 2.5 2.4 0.2
Automatic tightener fastening screws to cylinder block 45 5 4.5 0.5
Fixed tightener fastening screws to cylinder block 105 5 10.5 0.5
Fan support fastening screws to cylinder block 24.5 2.5 2.4 0.2
Starter fastening screws 44 4 4 0.4
Air heater on cylinder head 30 3 5 0.5
Hydraulic power steering pump gear fastening nut 105 5 10.5 0.5
Air conditioner compressor fastening screw to support 24.5 2.5 2.4 2.5
Alternator support superior fastening screw 71.5 4.5 7.1 0.4
Alternator bracket fastening screw to cylinder block 24.5 2.5 2.4 0.2
Water pipe unions 35 3.5
Water temperature sensor 32.5 2.5 3.2 0.2
Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly
C87 ENT M38.10
PART TORQUE
Nm kgm
Flywheel rev sensor fastening screw 84 0,8 0.2
Camshaft rev sensor fastening screw 84 0.8 0.4
P.D.E. solenoid connector fastening screw 1.62 0.3 0.1 0.3
Overboost pressure sensor fastening screw 82 0.8 0.2
Absolute pressure sensor fastening screw 22.5 2.5 2.2 0.2
P.W.M. control valve fastening screw/nut 82 0.8 0.2
Fuel/coolant temperature sensor 35 3.5
Coolant temperature indicator 23.5 2.5 2.3 0.2
Filter clogging sensor 10 1
Oil temperature switch 25 1 2.5 0.1
Oil pressure sensor 25 1 2.5 0.1
Electric wire fastening screw 82 0.8 0.2
Gear fastening screws to camshaft M14x50
First stage pre-tightening 40
Gear fastening screws to camshaft M14x50
Second stage pre-tightening 45;
Heater fastening screw 24.5 2.5 2.5 0.2
Gear fastening screws to camshaft
Gear fastening screws to camshaft
Alternator positive retaining nut M8x1.25 12.5 2.5 1.3 0.3
Starter terminal nut 30 M10x1.5 21 3.4 2.1 0.3
Starter terminal nut 50 M5x0.8 3.6 1 0.4 0.1
C87 ENT M38.10
Lower crankcase bolt tightening order diagram
Figure 1
First phase:
FRONT SIDE preliminary
tightening of
inner screws
(140 Nm)
80858
Second phase:
angle tightening
FRONT SIDE of inner screws
60
80858
Third phase:
FRONT SIDE angle tightening
of inner screws
60
80858
Fourth phase:
preliminary
tightening
FRONT SIDE of outer screws
(25 Nm)
80857
Fifth phase:
angle tightening
FRONT SIDE of outer screws
90
80859
C87 ENT M38.10
Diagram of cylinder head fixing screws tightening order

Figure 2
114259
Sequence
- First phase preliminary tightening 50 Nm Sequence as shown in figure;
- Second phase preliminary tightening 100 Nm Sequence as shown in figure;
- Third phase angle locking 90 Sequence as shown in figure;
- Fourth phase angle locking 75 Sequence as shown in figure.
Diagram of rocker arm shaft fixing screws tightening order
Figure 3
80861
Sequence
- First phase tighten the screws 1-2-3 until they bear down on the rocker arm shaft;
- Second phase preliminary tightening 40 Nm Sequence as shown in figure;
- Third phase angle locking 60 Sequence as shown in figure.
C87 ENT M38.10
Exhaust manifold bolt tightening order diagram

Figure 4
80862
Sequence
- Second phase preliminary tightening 55 Nm Sequence as shown in figure.
Diagram of feeder-line between exhaust Diagram of exhaust flange fixing screws

manifold and turbocompressor fixing nuts tightening order
tightening order
Figure 5 Figure 6
Exhaust manifold side nuts

- Tightening torque: 107 Nm Sequence B-D-A-C.
Turbocompressor side nuts

80864
- Tightening torque: 55 Nm Sequence 4-2-1-3.
- Tightening torque: 50 Nm Sequence 2-4-1-3.

C87 ENT M38.10
Diagram of heat exchanger fixing screws tightening order

Figure 7
147009
Sequence
- Second phase preliminary tightening 22 Nm Sequence as shown in figure.
Diagram of engine oil sump fixing screws tightening order

Figure 8
147010
- Tightening 50 Nm Sequence as shown in figure.
Diagram of rocker arm cap fixing screws tightening order

Figure 9
- Tightening 10 Nm Sequence as shown in figure.

C87 ENT M38.10
ATTENTION Figure 11
The operations described below refer to engines not
equipped with marinisation components.
Before securing the engine on the rotary stand:

- Remove the engine mountings
- Remove the engine cable
- Secure the engine to the rotary stand with the brackets
- Drain the lubricating oil from the oil sump.
143672
Remove the adapter for the oil filter (1) and the heat
exchanger (2).
Figure 10
Figure 12
114016
05_070_C
Unlock retaining screws (2) and remove head cover (1) to

Using an appropriate tool (1), operate in the direction of the reach injector and rail wiring.
arrow, and remove the belt (4) driving the water pump and
alternator.
- Automatic belt tightener support (2);
- Alternator (3);
- Fixed tightener (5);
- Water pump (6) and piping;
- Damping flywheel (7);
- Disconnect all electric connections and the sensors.
C87 ENT M38.10
Figure 13 Figure 15
114551
Apply extractor 99340051 (2) and remove seal (1). 114018
Unlock screws and remove front cover (3). Clean surfaces to be coupled to remove dirt and oil residuals.
Apply LOCTITE 275 silicone on gear casing (1) as shown in
the figure.
The sealant seam diameter must be 1.5 0.5/0.2.
Figure 16
Figure 14
114019
Use specific spanner to unlock screws (2) and remove gear

(3) complete with tune wheel.
Unlock nut (4) and remove control gear (5) of high pressure
pump.
Remove rpm sensor (1).
114015 ATTENTION
In case removal of gear (5) is difficult, release high pressure
Remove screws (1) and blow-by box (2). pump screws with light beater strokes on control shaft and
remove gear (5).
C87 ENT M38.10
Figure 17 Figure 19
114009
Use specific tool lock engine flywheel (2) rotation, unlock

retaining screws (1) and remove engine flywheel.
143673
Remove the high-pressure pump (1) and the starter motor

(2).
Figure 20
Figure 18
114020 45257
Unlock screws (1) and remove thrust plate (2).

Apply extractor 99340054 (2) and remove seal (1).
Use specific spanner to unlock screws (4) and remove relay
gear (5).
Remove high pressure pump mount flange (3).
C87 ENT M38.10
Figure 21 Figure 23
114022
143674
Unlock screws (1) and remove flywheel box (2).
Undo the screws (1) and remove the oil sump (2). Figure 25
114023
Remove screws (2) and double gear (3).

Remove retaining screw (5) and connecting rod (4).
Remove oil pump (1).
Figure 22
Figure 24
114024
114031b
Unlock screws and remove suction rose (1). - Unlock rocker arm shaft retaining screws (4).
- Disconnect fuel pipelines (1) from injector rail, fuel
supply line (2) of high pressure pump to rail and return
line (3).
C87 ENT M38.10
Figure 26 Figure 28
114025
45266
Apply tool 99360558 (1) to rocker arm shaft and remove

Remove camshaft and remove cylinder head retaining
shaft, remove crosspieces (3) from cylinder head.
screws.
Use metallic ropes to lift cylinder head (1) and remove seal
(2).
Figure 29
Figure 27
117690
Clean surfaces to be coupled to remove dirt and oil residuals.

Apply LOCTITE 275 (1) silicone on front cover (2) as shown
in the figure.
114027 The sealant seam diameter must be 1.5 0.5/0.2.
Remove retaining brackets (3) and remove injectors (4).
Remove retaining screws (1) and remove rail (2).
ATTENTION
Install gear casing within 10 min. from sealant application.
C87 ENT M38.10
Figure 30 Figure 32
114615
Use adequate hexagonal spanner, unlock screws (1 and 3)

and remove stiffening plate (2) as well as main journals (4).
115881
Rotate the block (1) to the vertical position. ATTENTION

Note down the assembly position of the top and bottom main
bearing shells since, if reusing them, they will need to be fitted
in the position found upon removal.
Figure 33
114035
Figure 31
Using tool 99360500 (1), remove the crankshaft (2).
Figure 34
47571
115882
Remove the main bearing shells (1), unscrew the screws and
Untighten screws (2) fixing the connecting rod cap (3) and take out the oil nozzles (2).
remove it. Remove the connecting rod-piston (1) assembly Remove the cylinder liners as described under the relevant
from the upper side. subheading on page 134.
Repeat these operations for the other pistons.
ATTENTION ATTENTION
Keep the big end bearing shells in their respective housings After disassembling the engine, thoroughly clean
and/or note down their assembly position since, if reusing disassembled parts and check their integrity.
them, they will need to be fitted in the position found upon Instructions for main checks and measures are given in the
removal. following pages, in order to determine whether the parts can
be re-used.
C87 ENT M38.10
CYLINDER BLOCK Figure 37

Checks and measurements
Figure 35 (Demonstration)
225036
34994
A = Selection class 117 117.012 mm
B = Selection class 117.010 117.022 mm
Internal diameter of the cylinder liners is checked for X = Selection class marking area
ovalization, taper and wear, using a bore dial (1) centesimal
gauge 99395687 (2) previously reset to ring gauge (3), In case of maximum wear >0.150 mm or maximum
diameter 117 mm. ovalization >0.100 mm compared to the values indicated in
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
CAUTION
CAUTION
If dia.117 mm ring gage is not available, use a micrometer.
Cylinder liners are equipped with spare parts with A
selection class.
Figure 36 Figure 38
114035 114037
1 = 1st measuring A = 130.500 to 130.525 mm

2 = 2nd measuring B = 129.510 to 129.535 mm
3 = 3rd measuring C = 130.461 to 130.486
D = 129.475 to 129.500 mm
Carry out measurings on each cylinder liner at three different
The figure shows the outer diameters of the cylinder liners
levels and on two (A-B) surfaces, to one another
and the relative seat inner diameters.
perpendicular, as shown in figure.
The cylinder liners can be extracted and installed several
times in different seats, if necessary.
C87 ENT M38.10
CYLINDER LINERS
Figure 39
114038
CYLINDER BLOCK ASSEMBLY WITH CHROME-PLATED CYLINDER LINERS

Figure 40
114039
CYLINDER LINERS MAIN DATA
Selection class A mm 117.000 to 117.012

B mm 117.010 to 117.022
C87 ENT M38.10
Replacing cylinder liners Figure 43

Removal
Figure 41
77812
Check cylinder barrel protrusion with tool 99360334

(1-2-3-4) and tighten screw (1) to 170 Nm.
47577
With dial gauge 99395603 (5) placed on base 99370415 (6).
Measure the cylinder barrel protrusion compared to the
Place details 99360706 (1 and 2) and plate 99360724 (4) as
shown in the figure, by making sure that the plate (4) is cylinder head supporting plane, it must be 0,035 to 0,065 mm
properly placed on the cylinder liners. (Figure 44); otherwise replace the adjusting ring (1,
Figure 42) fitted with spare parts having different thickness.
Tighten the screw nut (1) and remove the cylinder liner (3)
from the block.
Figure 44
Fitting and checking protrusion
Figure 42
114041
CYLINDER LINER PROTRUSION
Figure 45 (Demonstration)
16798
Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2);
lubricate lower part of liner and install it in the cylinder unit
using the proper tool.
ATTENTION
The adjustment ring (1) is supplied as spare parts in the
following thicknesses: 0.08 mm - 0.10 mm - 0.12 mm. 35012
When the installation is completed, block the cylinder liners

(1) to the block (2) with studs 99360703 (3).
C87 ENT M38.10
CRANKSHAFT
Figure 46
Upper main journal half bearing
Lower main journal half bearings

114042
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
Figure 47 Figure 48
114043 114044
X. Detail of main journals connections Y. Detail of crank pins connections

C87 ENT M38.10
Measuring main journals and crank pins Figure 50

Before grinding the crank pins using a micrometer (1),
measure the main journals and the crank pins (2) and decide,
on the basis of the undersizing of the bearings, the final
diameter to which the pins are to be ground.
Figure 49
47536
MEASURING CRANK PINS
During grinding, pay attention to journal and crank pins values
specified in figures 68 and 69.
47535
MEASURING THE MAIN JOURNALS

CAUTION CAUTION
It is advisable to enter the values found in a table (Figure 51). All journals and crank pins must also be ground to the same
undersizing class, in order to avoid any alteration to shaft
balance.
Figure 51
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
MIN.
MAX.
MIN.
MAX.
CRANK PINS 114045

C87 ENT M38.10
PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:

- Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount.
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 52 at top).
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure 52 at bottom).
- Each of these digits may be 1, 2 or 3.
Figure 52
CLASS MAIN BEARING HOUSING

NOMINAL DIAMETER
99.000 to 89.009
99.010 to 99.019
99.020 to 99.030
114046
C87 ENT M38.10
Selecting the main and big end bearing shells

CAUTION
To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described hereunder.
This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the bearing shells are selected The following tables give the specifications of the main and
in classes of tolerance marked by a coloured sign big end bearing shells available as spares in the standard sizes
(red-green red/black green/black). (STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
Figure 53
STD +0.127
red 1.994 to 2.002
red/black 2.057 to 2.065
green 2.002 to 2.010
green/black 2.065 to 2.073
yellow* 2.010 to 2.018
yellow/black* 2.073 to 2.081
STD +0.127
red 2.968 to 2.978
red/black 3.031 to 3.041
green 2.978 to 2.988
green/black 3.041 to 3.051
yellow* 2.988 to 2.998
yellow/black* 3.051 to 3061
* Fitted in production only and not supplied as spares

C87 ENT M38.10
DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 54 at top):
- The first number, of five digits, is the part number of the shaft.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins
they refer to (Figure 54 at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the
status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the
main journals they refer to (Figure 54 at bottom).
Figure 54
CRANKPIN
CLASS
NOMINAL DIAMETER
81.915 to 81.925
81.925 to 81.935
81.935 to 81.945
CLASS MAIN JOURNALS

NOMINAL DIAMETER
92.970 to 92.980
92.980 to 92.990
92.990 to 93.000
C87 ENT M38.10
Selection of main half-bearings (nominal diameter pins)
After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:
Figure 55
STD.
114048
1 2 3
green green yellow
1
green yellow yellow
red green green
2
green green yellow
red red green
3
red green green
114055
C87 ENT M38.10
Selection of main half-bearings (rectified pins)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type
required for this undersizing.
Figure 56
red/black =
mm 3.031 to 3.041
green/black =
mm 3.041 to 3.051
-0.127
green/black =
mm 3.0513 to 3.061
1 2 3
92.843 green/black green/black yellow/black
1
92.853 green/black yellow/black yellow/black
92.853 red/black green/black green/black

2
92.863 red/black red/black green/black

3
C87 ENT M38.10
SELECTING THE BIG END BEARING SHELLS Figure 57

(JOURNALS WITH NOMINAL DIAMETER)
There are 4 references on the connecting rod casing in the
positions illustrated:
1. Coloured mark for identifying the weight
2. Coloured mark for identifying the diameter grade
3. Positioning stud visible from the front of the engine
4. Progressive number for identifying the connecting rod
CAUTION
The identification colours of the marks are given in the table
on page 31.
The number, indicating the class of diameter of the bearing

shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal
by following the indications in the table (Figure 58).
47557
Figure 58
STD.
1 2 3
Class yellow blue
green
green green yellow

1
green yellow yellow
red green green
2
green green yellow
red red green
3
red green green
C87 ENT M38.10
Selection of connecting rod half-bearings (rectified pins)

If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings
identified according to the relative table.
Figure 59
red/black =
mm 2.057 to 2.065
green/black =
mm 2.065 to 2.073 -0.127
green/black =
mm 2.073 to 2.081
1 2 3
1
81.799 green/black yellow/black yellow/black

2
81.809 red/black red/black green/black

3
C87 ENT M38.10
Replacing the timing control gear and the oil Figure 62

pump
Check that the teeth of the gears are not damaged or worn,
otherwise remove them using the appropriate extractor.
Figure 60
114034
Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
115883
CAUTION
Before fitting the gear, spread Loctite type 603 on
approx. 5 mm wide band on crankshaft, at 30 mm from
contact surface.
After fitting the gear (1) on the crankshaft (2), heat it for
~15 minutes in an oven at temperature not higher than
180C.
Let them cool down after the installation.
If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.
Checking main journal installation clearance
Figure 61 Figure 63
114049 114050
Fit the oil jets (2) aligning the dowel with the opening (3) in Place bearing halves (1) on main journals (2).
the crankcase.
Check the installation clearance between the main journals
Position the half-bearings (1) and the thrust washers on the and the relative bearings as follows.
main journal supports as illustrated in Figure 46.
C87 ENT M38.10
Figure 64 Figure 65
114051 114615
Fit sized wire sections (2) on crankshaft (3) parallel to - Position the main journal caps (4) and fit the
longitudinal axis. strengthening plate (2) following the procedure
described:
Install main journals (1).
- Tighten the inner bolts and then the outer bolts by hand
starting from main journal 7 and continuing until main
journal 1.
- Tightening the bolts using torque wrench always starting
from main journal 7 and continuing until main journal
1:
1st stage: 140 Nm
2nd stage 60+60
Checking crankshaft end float
Figure 66
47588
End float is checked by placing a magnetic dial gauge (1) on

the crankshaft (2), as shown in the figure.
If the value obtained is higher than specified, replace the rear
thrust half-bearings and repeat this check.
C87 ENT M38.10
PISTON CONNECTING ROD ASSEMBLY
Figure 67
81041
PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring
with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston.
Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal
Figure 69
Figure 68
126311 126312
Removal of the piston split rings (2) using the pliers Remove the piston pin split rings (2) using the round tipped
99360184 (1). pliers (1).
C87 ENT M38.10
Figure 70 Figure 71
49025 32618
Remove the piston pin (1). Measuring the gudgeon pin diameter (1) with a micrometer
(2).
If removal is difficult use the appropriate beater.
Conditions for correct gudgeon pin-piston

coupling
Figure 72
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.
C87 ENT M38.10
zl
Figure 73
114053
MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0,6 0,15 Figure 76
The dimension is measured on a of 113 mm
Piston rings
Figure 74
3513
The sealing ring (2) of the 1 cavity is trapezoidal. Clearance

X between the sealing ring and its housing is measured by
placing the piston (1) with its ring in the cylinder barrel (3),
so that the sealing ring is half-projected out of the cylinder
16552 barrel.
Check the thickness of the piston ring (2) using a micrometer
(1). Figure 77
Figure 75
36134
Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
16552
Check the clearance between the sealing rings (2) and the If the distance between ends is lower or higher than the value
relative piston housings (1) using a thikness gauge (3). required, replace split rings.
C87 ENT M38.10
CONNECTING ROD
CAUTION
When fitting the connecting rods, check that all of them are of same weight class and from the same supplier. The connecting
rod/cap is of torn type; before assembly verify that the connecting rod is not damaged. Each connecting rod can assembled
with the relative cap only. If the cap is assembled on the reverse side, the connecting rod must be rejected.
Figure 78
114054
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

* Values to be obtained after installing the bush
1 Between the connecting rod bush and the connecting rod profile there must be a distance > 0.4 mm.
2 On the external breaking line, gap area allowed must be < 5 mm2.
3 No cracks are allowed in the threaded area.
C87 ENT M38.10
Figure 79
Version C87 ENT M38.10
115884
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from
the front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
GRADE A
Yellow 3450 g - 3470 g 85.997-86.005 Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE B
Green 3471 g - 3490 g 85.997-86.005 Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE C
Blue 3491 g - 3510 g 85.997-86.005 Green
86.006-86.013 Blue
C87 ENT M38.10
Figure 80
Version C87 ENT M62.10
115884
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from
the front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
GRADE A
Yellow 3308 g - 3338 g 85.997-86.005 Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE B
Green 3339 g - 3368 g 85.997-86.005 Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE C
Blue 3369 g - 3398 g 85.997-86.005 Green
86.006-86.013 Blue
C87 ENT M38.10
Mounting the connecting rod - piston Mounting the piston rings

assembly
Carry out the steps for removal described on pages 146 and Figure 82
147 in reverse order.
Figure 81
49029
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
117694 The rings need to be mounted with the word TOP (4)
facing upwards. Direct the ring openings so they are
staggered 120 apart.
ATTENTION
The connecting rod screws can be reused as long as the

diameter of the thread is not less than 11.4 mm.
C87 ENT M38.10
zszl
CYLINDER HEAD
Fitting connecting rod - piston assemblies in Figure 83

the cylinder liners
With the aid of the clamp 99360605 (1, Figure 83), fit the
connecting rod - piston assembly (2) in the cylinder liners,
according to the diagram of Figure 84, checking that:
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.
60616
Checking piston protrusion

On completing assembly, check the protrusion of the pistons
from the cylinder liners; it must be 0.873 to 1.177 mm.
CAUTION
As spares, class A pistons are provided and can be fitted also
to cylinder barrels belonging to class B.
Figure 84
60615
ASSEMBLY DIAGRAM OF CONNECTING ROD - PISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod - piston assembly - 2. Area of punch marking on the top of the piston,
symbol showing assembly position and selection class - 3. Connecting rod punch mark area
C87 ENT M38.10
Checking assembly clearance of big end pins Before taking down the cylinder head, check the seal using
To check the clearance proceed as follows: the appropriate tool; in case of leakage replace the cylinder
head.
- Connect the connecting rods to the relative main
journals, place a length of calibrated wire on the latter; Valve removal
Figure 86
Figure 85
81061
Install and fix tool 99360264 (2) with bracket (4); tighten by
81060
lever (1) until cotters are removed (3); remove the tool (2)
and the upper plate (3), the spring (6) and the lower plate (7).
- Install the connecting rod caps (1) with half-bearings; Repeat the operation on all the valves. Turn the cylinder head
tighten the connecting rod cap fixing screws (2) to upside down and remove the valves (8).
50 Nm (5 Kgm) torque. By tool 99395216 (3), tighten
the screws further at 90 angle;
- Remove the caps and check the clearance by comparing Checking the planarity of the head on the
the width of the calibrated wire with the scale calibration cylinder block
on the envelope containing the wire.
Figure 87
81062
The planarity (1) is checked using a ruler (2) and a thickness

gauge (3). If deformations exist, surface the head using proper
surface grinder; the maximum amount of material to be
removed is 0.2 mm.
CAUTION
After leveling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
C87 ENT M38.10
VALVE Figure 89
Removing deposits and checking the valves
Figure 88
92841
MAIN DATA - VALVES AND VALVE GUIDES

48625
* Values to be obtained after installing the valve guides
Remove carbon deposits using the metal brush supplied.
Check that the valves show no signs of seizure or cracking. Check, by means of a micrometer, that valve stem diameters
Check the diameter of the valve stem using a micrometer are as specified; if necessary, grind the valves seat with a
(see Figure 89) and replace if necessary. grinder, removing the minimum quantity of material.
VALVE GUIDES
Figure 90
47509
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES
* Values to be obtained after installing the guide valves
C87 ENT M38.10
REPLACING INJECTOR HOLDER CASES
Replacing of valve guides Removal

Install by means of tool 99360288 equipped with part
99360288, which determines the exact installation position Figure 91
of valve guides into the cylinder heads; if they are not
available, install the valve guides in the cylinder head so that
they project out by mm 16.3 to 16.7 (Figure 90).
After installing the valve guides, smooth their holes with
sleeker 99390310.
81067
To replace the injector case (2), act as follows:

- Thread the case (2) with tool 99390804 (1).
Carry out operations described in figs. 91-94-95-96 by fixing
tools to the cylinder head by means of bracket A.
C87 ENT M38.10
Figure 92 Mounting
Figure 94
81068 8107
- Fasten extractor 99342149 (2) to case (2), by tightening - Lubricate sealing rings (3) and fit them to the case (4);
the nut (1), and pull out the case from cylinder head. fix tool 99365054 (2) to the cylinder head by means of
bracket A, install the new case, tighten the screw (1),
upsetting the case lower part.
Figure 93
Figure 95
81069
- Remove any residue, with tool 99390772 (2), from the

cylinder head groove.
81071
- Adjust the casing hole (3) with borer 99394043 (1) and
guide bushing 99394045 (2).
C87 ENT M38.10
Figure 96 Figure 98
115891 114056
- Through miller 99394044 (1) and bushing 99394045 (2), INSTALLATION DIAGRAM FOR
ream the injector seat in the case (3), check the injector INJECTOR CASE
protrusion from the cylinder head plane which must be
1.2 to 1.5 mm.
Checking protrusion of injectors
Figure 97
47585
Using dial gauge (1), check the protrusion of the injector (2)
which must be 1.2 to 1.5 mm.
C87 ENT M38.10
zl
TIMING GEAR Idler gear

Camshaft drive
Figure 99 Figure 101
114210 114211
TIMING CONTROL COMPONENT PARTS

1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -
5. Camshaft control gear - 6. Idler gear -
7. Twin idler gear - 8. Drive shaft driving gear.
Twin idler gear
Figure 102
Intermediate gear pin
Figure 100
114212
86926 Replacing the bushings

Rated assembling play between idler gear bushings and pins:
0.040 0.080 mm. Bushings (1, Figures 100-101) can be replaced when they are
worn. Put up the bushing, then grind it so as to bring it to a
dimension of 65.010 0.10 mm.
CAUTION
Bushing fitting in gears (2, Figures 100-101) must be
performed in arrow direction, placing them as shown in
figures.
C87 ENT M38.10
Checking cam lift and pin alignment
Figure 103
81088
Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on
page 111.
Figure 104
81075
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not
exceed 0.030 mm.
If misalignment exceeds this value, replace the shaft.
Figure 105
81076
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.
C87 ENT M38.10
CAMSHAFT
Figure 106
114213
MAIN DATA - CAMSHAFT AND TOLERANCES

The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the
shaft and the relative bushes.
TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricity or coaxial alignment
OSCILLATION Circular oscillation
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT
SECONDARY
TIMING GEAR
Figure 107
114214
MAIN DATA - CAMSHAFT BUSHES AND RELATIVE BLOCK SEATS

* Bush inner diameter after installation
The bush surfaces must not show any sign of seizing or Measure the bush inner diameters with a baremeter and replace
scoring; if they do replace them. them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper tool
99360505.
C87 ENT M38.10
Use beater 99360505 to change bushings Fitting the valves and oil seal ring
Removal
Figure 110
Figure 108
114280
Use tool 99360505 (3) fitted as shown in fig. to remove

bushings (2).
Accurately position beater during removal phase.
VALVE SPRINGS
87051
Fitting
Lubricate the valve stem and insert the valves in the
For fitting, reverse operations performed for removal, with
respective valve guides; fit the lower caps (1). Use tool
care to make lube hole (1), drilled on bushing, coincide with
99360294 to fit the oil seal (2) on the valve guides (3) of the
corresponding hole in housing.
exhaust valves; then, to fit the valves, proceed as follows.
CAUTION
Figure 109 Should valves not have been overhauled or replaced,
remount them according to numbering performed on
dismounting.
Intake valves are different form exhaust valves in that they
have a notch placed at valve head centre.
Figure 111
143678
MAIN DATA TO CONTROL EXHAUST AND

DISCHARGE VALVE SPRING
86290
- fit springs (6) and the upper plate (5);

- apply tool 99360264 (2) and block it with bracket (4);
tighten the lever (1) until cotters are installed (3),
remove tool (2).
C87 ENT M38.10
ROCKER SHAFT
Figure 112
114216
The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker
arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two
valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker
a rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.
Shaft
Figure 113
114217
MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
Rocker
Figure 114
114219
DISCHARGE VALVE ROCKER

Figure 115
114218
EXHAUST VALVES ROCKER

The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.
C87 ENT M38.10
LUBRICATION CIRCUIT COMPONENTS Overpressure valve

Oil pump
Figure 118
Figure 116
1 6N
324 9N
43.65
33.5
22.95
22.95
117716
114245
MAIN DATA TO CHECK THE OVERPRESSURE
The oil pump (1) cannot be overhauled. On finding any VALVE SPRING
damage, replace the oil pump assembly.
See under the relevant heading for replacing the gear (2) of
the crankshaft.
Figure 117
112327
OIL PUMP CROSS-SECTION

1. Overpressure valve Start of opening pressure 10.1 0.7 bars.
C87 ENT M38.10
Engine oil filter adapter
Figure 119
143676
Filter by-pass valve

Figure 120
73545
Valve opens quickly at 3,4 0,3 bar pressure.

C87 ENT M38.10
Oil pressure control valve Figure 123

Figure 121
168 9
308 15
63
51
36.4
73542 88819
The oil pressure control valve is located on the left-hand side MAIN DATA TO CHECK THE OIL PRESSURE
of the crankcase. CONTROL VALVE SPRING
Start of opening pressure 5 bars.
Heat exchanger
Figure 122
143675
1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4. Oil filter

C87 ENT M38.10
COMPONENTS OF THE COOLING SYSTEM
Description and operation on Section 1. Thermostatic valve

Cooling by forced circulation obtained with centrifugal pump, The valve is calibrated to start opening the channel to the sea
driven by the drive shaft through a Poli-V belt. Liquid water heat exchanger at a temperature of 68 2 C and to
circulation is regulated by a thermostatic valve. shut the channel to the coolant pump completely at the
temperature of 78 2 C.
Check the valve works properly; replace it if in doubt.
Water pump
Figure 124
81101
1. Impeller - 2. Control Pulley

Make sure that the pump casing has no cracking or water
leakage; otherwise, replace the entire pump.
05_148_C 05_149_C
Low temperature liquid High temperature liquid
1. By-pass flow to the engine - 2. Flow from the engine - 3. Flow from the exhaust manifold -
4. Flow to the exhaust manifold - 5. Flow to the sea water heat exchanger.
C87 ENT M38.10
ASSEMBLY Figure 128
Figure 127
114257 42566
Check that pistons 1-6 are exactly at T.D.C.

Install front cover (1) and lock retaining screw at required Place seal (2) on cylinder block.
torque. Install cylinder head (1) and lock screws as shown in figures
below.
CAUTION
Removed screws must not be used again.
Employ new screws only.
Figure 129
Figure 130
114258
114259
Cylinder head retaining screw locking sequence diagram.

Secure seal (1), install special tool 99346260 (2), lock nut (3)
to secure seal (1).
C87 ENT M38.10
45267
- Pre-lock by torque wrench (1): 145833

1st phase: 50 Nm (5 kgm);
2nd phase: 100 Nm (10 kgm).
Install oil pump (1), double gear (3) complete with
connecting rod (4) and lock screws (2) in two phases:
pre-lock 30 Nm
90 angle lock
Figure 132
45268
- Angle locking by means of tool 99395216 (1):

3rd phase: 90 angle
4th phase: 75 angle.
C87 ENT M38.10
Figure 134
114260
CAUTION 5. Fit pipes on injectors and head locking fittings by hand.

The previously removed pipes ca no longer be refit and must 6. Lock fittings on rail (A, C) at required torque .
be replaced.
7. Lock fittings on injectors and head (B, C) at required
Lubricate the injector fastening O-Rings using the following
torque.
lubricants: PDE SILIKONFETT 22, NLG 12, PDE
LUBRICOMET GR 220 NLG12.
1. Install rail on cylinder head and lock retaining screws by TYPE DESCRIPTION LOCK TORQUE
hand. A M18 x 1.5 40 2 Nm
2. Install injectors in correct position and lock to required B M14 x 1.5 35 2 Nm
torque. C M16 x 1.5 40 2 Nm
CAUTION
Check that the injectors (2) are equidistant from the springs
(1). Distance X which separates them should always be the CAUTION
same.
After fitting the high-pressure pipelines, during the following
20 hours of work, frequently check engine oil level (IT MUST
3. Install pipes on rail and lock fittings by hand. NOT INCREASE).
4. Lock rail to cylinder head retaining screws at required
torque.
C87 ENT M38.10
114261

Apply LOCTITE 275 (2) silicone on gear casing (1) as shown
in the figure. 114263
The sealant seam diameter must be 1.5 0.5/0.2 mm.

Apply LOCTITE 275 silicone on gear casing (1) as shown in
the figure.
CAUTION
The sealant seam diameter must be 1.5 0.5/0.2 mm.
Install gear casing within 10 min. from sealant application.
CAUTION
Figure 136 Install gear casing within 10 min. from sealant application.
Figure 138
114264
114262
Apply gage 99395221 (1) to check and adjust position of
high-pressure pump connection flange (2).
Use torque wrench to lock screws (1) at required torque.
Fix flange screws (2) at required torque.
C87 ENT M38.10
High pressure pump installation Figure 141

Figure 139
45258
114272
Secure seal (1), install special tool 99346260 (2), lock nut (3)
Install high-pressure pump (1) on flange (2). to secure seal.
Engine flywheel installation

ENGINE FLYWHEEL
CAUTION CAUTION
If toothing on engine flywheel for engine start-up is very Crankshaft has a reference pin that must match with related
damaged, change crown wheel. housing on engine flywheel.
Refit crown wheel after heating up at approx. 200C.
Figure 140
114265
DETAIL OF PISTON POSITION STAMPING ON ENGINE FLYWHEEL

A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC - B. Hole on flywheel with a notch, corresponding to
piston 1-6 TDC - C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC - D. Hole on flywheel with 2
notches, position corresponding to 54.
C87 ENT M38.10
Figure 142 This condition is obtained when:

1. the opening with one reference (5) for the engine
flywheel (4) is visible from the inspection window;
2. tool 99360612 (1), through housing (2) of engine rpm
sensor, inserts in hole (3) drilled on engine flywheel (4).
Otherwise, adjust engine flywheel orientation (4).
Remove too 99360612 (1).
145832
Position flywheel (1) on crankshaft, lubricate screws (2)

threading with engine oil and lock them.
Stop rotation using specific tool.
Lock screws (2) in three phases.
1st phase: pre-lock with torque wrench (3) at 100 Nm torque
(10 kgm).
49036
2nd phase: 60 angle locking using tool 99395216 (1).
Camshaft installation
Figure 144
114267
Install camshaft (3) and orient it with references ()

positioned as in the figure.
Clean the matching surfaces of the plate (1) to remove
impurities and oil residues.
Apply silicon LOCTITE 275 (6) on the plate (1) as shown in
the picture.
CAUTION
Take care NOT to get sealant on the inner groove (5).
The diameter of the sealant bead should be 1.5 - 0.5/0.2 mm.

Fit the plate (1) within 10 mins of applying the sealant with
72436
the gasket (2) and tighten the bolts (4) to the recommended
Position crankshaft with pistons 1 and 6 at TDC. torque.
C87 ENT M38.10
zs
Figure 146 TIMING CAMSHAFT AND FLYWHEEL

USING TOOL 99395223
Timing camshaft
Figure 148
114269
Apply gage 99395222 (1), check and adjust position of

connecting rod (3) for relay gear, lock screw (2) at required
torque.
115064
Rotate the crankshaft with the tool 99360341 (3, Figure 155)
so that the opening marked with two references (5) is visible
from the lower inspection window in the flywheel cover
casing.
In this condition, insert the tool 99360612 (1) via the housing
(2) for the engine rpm sensor in the opening (3) in the engine
flywheel (4).
Figure 147
Figure 149
114270 116052
Refit relay gear (2) and lock screws (1) using six-splined Fit the tool 99395223 (1) at the front of the camshaft.
spanner at required torque.
CAUTION
The relay gear (2) bushing can be replaced when worn out.
After securing bushing, grind it to reach dia. 58.010 0.10 mm.
C87 ENT M38.10
116055
Install crosspieces (1) on valve rod.

116053
Rotate the tool (1) 99395223 in order to insert the pin (3) CAUTION
in the opening (2, Figure 149) in the head. Fasten the tool
(1) 99395223 using two M8x1.25 bolts (2). Before refitting rocker arm shaft assembly, check that all
adjustment screws have been fully unlocked.
Figure 151
Figure 153
114025
117691
Apply tool 99360558 (1) to rocker arm shaft (2) and install
Fit the camshaft drive gear (1) so that the fastening openings shaft on cylinder head.
in the shaft are aligned with the slots (2) in the drive gear. Lock retaining screws at required torque.
Position the gear (1) taking care to position the spokes (4)
as illustrated. This operation is necessary in order to be able
to fit the flywheel correctly which can only be fitted in one
position in relation to the gear.
Tighten the fixing bolts (3).
C87 ENT M38.10
Timing flywheel TIMING CAMSHAFT AND FLYWHEEL

WITHOUT TOOL 99395223
Figure 154
Timing camshaft
Figure 155
145834
Fit the high pressure pump gear (5) tightening the nut (4) to
torque.
Use the flat washer (PN 17095914) in conjunction with the
nut (4) replacing the one supplied with the Bosch CP3 pump.
Fit the flywheel (6) so that the toothe marked with the arrow
() is in line with the sensor housing (2).
To check that the position is correct, insert tool (1)
99360613 in the timing sensor (2) housing.
Proceed with tightening the bolts (3). 114279
Secure special tool 99360341 (3) to gear casing.

Remove the tools 99395223, 99360612 and 99360613.
CAUTION
The arrow indicated engine rotation direction.
Use tool above to rotate engine flywheel (1) in engine
rotation direction to bring cylinder 1 piston approx. to TDC
in blast phase.
This condition is reached when hole with notch (4),
following hole with two notches (5) drilled on engine
flywheel (1), is visible through manhole (2).
Figure 156
71774
The exact position of piston no.1 at TDC is obtained when,

in conditions described above, tool 99360612 (1), through
engine rpm sensor housing (2), inserts in hole (3) drilled on
engine flywheel (4).
Otherwise, rotate engine flywheel (4) to adjust its
orientation.
C87 ENT M38.10
114276
Install crosspieces (1) on valve rod.
CAUTION
Before refitting rocker arm shaft assembly, check that all
adjustment screws have been fully unlocked.
Figure 160
115063
Rotate the camshaft so that the openings at the rear of the

engine are arranged in the configuration illustrated in the
diagram.
Figure 158
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and install
shaft on cylinder head.
Lock retaining screws at required torque.
Remove tool 99360612 (1, Figure 149).
Figure 161
117691
Install gear (1) controlling camshaft so that fastening holes on

shaft coincide with slots (2) on control gear.
CAUTION
Position the gear (1) taking care to position the spokes (4)
as illustrated.
This operation is necessary in order to be able to fit the
flywheel correctly which can only be fitted in one position
in relation to the gear. 117693
Clean the surface of the parts to be joined removing

impurities and oil residuals. Apply silicon LOCTITE 275 (1)
Lock retaining screws (3). on the front cover (2) as shown in the picture. The diameter
of the sealing string must be 1.5 0.5/0.2 mm.
C87 ENT M38.10
115064
Rotate crankshaft to check conditions below:

115064
1) hole identified with two notches (5) is visible through
manhole; Camshaft is timed if conditions below are found at cam lift
values 4.70 0.05:
2) fixture 99360612 (1) through housing (2) of engine rpm
sensor inserts in hole (3) on engine flywheel (4). 1) hole identified with two notches (5) is visible through
manhole;
CAUTION 2) fixture 99360612 (1) through housing (2) of engine rpm
sensor inserts in hole (3) on engine flywheel (4).
To recover the clearances, rotate the crankshaft in a
clockwise direction until the opening with the two
references is passed and then rotate in the opposite
direction to produce the conditions described above.
Figure 165
Figure 163
106535
114281
Position the dial gauge with a magnetic base (1) with the
(flat-based) rod positioned on the roller (2) for the rocker
arms which controls the exhaust valve for cylinder no. 3 and In case conditions shown in Figure 163 and shown at paras
apply a pre-loading of 6 mm. 1 and 2 are not found, operate as follows:
CAUTION 1) release screws (2) securing gear (1) of camshaft to as to
During the measurement the rod for the dial gauge should make control gear and camshaft independent;
always be perpendicular to the engine axis and NOT to the 2) conveniently operate on engine flywheel so as to obtain
surface of the head. conditions indicated at paras 1 and 2, Figure 164,
considering that cam lift value must remain unchanged;
Using tool 99360341 (3, Figure 155), rotate crankshaft
clockwise till dial gage arrow reaches minimum value (max 3) lock screws (2) and repeat control as already described;
cam lift), after which it no longer varies. 4) lock screws (2) at required torque.
Zero set dial gage.
Rotate engine flywheel anticlockwise till dial gage reads
camshaft cam lift value = 4.70 0.05 mm.
C87 ENT M38.10
Timing flywheel Figure 167

Figure 166
114275
CAUTION
Pipes previously removed ca no longer be refit.
Change them.
Install fuel supply pipeline (1) from high pressure pump to rail.
Lock nuts at 35 Nm torque.
CAUTION
After high-pressure pipe installation, during the following
20 hours of work, frequently check engine oil level (IT MUST
NOT INCREASE).
Figure 168
114284
Install gear (7) of high pressure pump and lock nut (8) at
required torque.
CAUTION
When refitting, use the flat washer (PN 17095914) in
conjunction with the nut (4) replacing the one supplied with
BOSCH pump CP3.
Fit the flywheel (4) so that the tooth marked with the arrow
() is in line with the sensor housing (6). 114285
Rotate crankshaft and bring cylinder n.1 piston to Install centrifugal filter (1) on tune wheel and lock screws (2)
compression phase at TDC: Rotate flywheel opposite to at required torque.
regular rotation direction by 1/4 of rev. Figure 169
Rotate flywheel again in regular rotation direction till hole
identified by double notch (2) shows through inspection hole
under flywheel cover box.
Insert tool 99360612 (1) in flywheel sensor housing (3).
Insert tool 99360613 through phase sensor housing (6) on
tooth machined on tune wheel.
In case tool (6) is difficult to insert, unlock screws (5) and
orient tune wheel (4) to properly match the tooth.
Lock screws (5).
114286
Install timing cover (1) and lock retaining screws (2) at

required torque.
C87 ENT M38.10
zl
Intake and exhaust rocker arm clearance Figure 171

adjustment
Figure 170
114287 114288
Install blow-by body (1) with related seal and lock screws (2)
Adjustment of clearance between rocker arms and at required torque.
intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted; Install cover (3) and lock screws (4) at required torque.
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5
and 3-4.
In order to perform these operations correctly, refer to Figure 172
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in Characteristic and data tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
IGNITION ORDER 1-4-2-6-3-5
START AND BALANCE ADJUST

ROTATION VALVES OF CLEARANCE
CLOCKWISE CYLINDER No. OF VALVES
CYLINDER No.
1 and 6 at TDC 6 1
120 3 4
120 5 2
120 1 6
120 4 3
117692
120 2 5
CAUTION Clean the surface of the parts to be joined removing

impurities and oil residuals. Apply silicon LOCTITE 406
In order to correctly carry out adjustments above, it is within the check valve (2) housing (1) and on the Blow-by
mandatory to perform the sequence indicated in the table, (3) as shown in the picture.
checking exact positioning at each phase by means of pin
99360612.
C87 ENT M38.10
114016
Install cylinder head cover (1) and lock screws (2) at required
115880 torque following order shown in Figure 178 diagram.
Fit the head internal electric wire (injectors+pressure sensor)

passing it through the opening (5, Figure 171) and securing Figure 176
it using bands as illustrated in the diagram ().
17 14 13 1 4 5 8
18 9
19 10
20 11
16 15 12 2 3 6 7
Figure 174
117695
Rotate the engine

Before assembling the suction rose, it is necessary to seal the contact area (1) between basement, flywheel casing and front cover
with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing impurities and oil residuals.
Apply silicon LOCTITE 275 (1) as shown in the picture. The diameter of the sealing string must be 1.5 0.5/0.2 mm.
C87 ENT M38.10
114031b
Install suction rose (1).

05_070_C
Figure 178
Installing the following components:

belt tensioner (2), alternator (3), fixed tightener (5), water
pump (6), damping flywheel (7).
To install auxiliary organ drive belt (4), using the appropriate
tool (1) loose the tensioner, as shown by arrow; insert the
belt, verifying that it is correctly set onto the pulleys. Release
the tensioner.
CAUTION
Automatic tensioners do not require further adjustments
after the installation.
143674
Fit the oil sump (2), tightening the screws (1) to the prescribed
torque.
Figure 179
Complete the engine by restoring the following components:

- Marinisation components (see relevant chapter)
- Fuel filter
- Engine cable
- EDC control unit
- Oil dipstick
- Engine mountings
Refill the engine with the required quantity of oil and coolant.
143672
Fit the oil filter adapter (1) and the heat exchanger (2).
C87 ENT M38.10
OCTOBER 2010 SAFETY REGULATIONS C87 ENT M62.10 9.183
SECTION 9
SAFETY REGULATIONS
Page
SAFETY REGULATIONS . . . . . . . . . . . . . . . . 185
Standard safety regulations . . . . . . . . . . . . . . . 185
Accident prevention . . . . . . . . . . . . . . . . . . . . 185
During maintenance . . . . . . . . . . . . . . . . . . . . 185
Respecting the Environment . . . . . . . . . . . . . 186

C87 ENT M38.10
9.184 C87 ENT M62.10 SAFETY REGULATIONS OCTOBER 2010

C87 ENT M38.10
OCTOBER 2010 SAFETY REGULATIONS C87 ENT M62.10 9.185
SAFETY REGULATIONS
Standard safety regulations - Put rags smeared with oil, diesel fuel, or solvents in
Pay particular attention to some precautions that must be fireproof containers;
followed by all means in any working place and whose - Do not carry out any intervention you have not been
non-observance will make any other measures useless or not given all necessary instructions for;
sufficient to ensure safety to the personnel in charge of
maintenance. - Do not use any tool or equipment for any operation
different from the ones they have been designed and
- Be informed and also inform personnel of the laws in provided for. Serious injury may occur;
force regulating safety, by making informative
documentation available for consultation; - In case of test or calibration operations requiring the
engine to be in operation, ensure that the area is
- Keep working areas as clean as possible, and ensure sufficiently ventilated or use specific aspirators to
adequate ventilation; eliminate exhaust gas. Danger: poisoning and death.
- Ensure that working areas are provided with emergency
kits. These must be clearly visible and always fitted with During maintenance
adequate sanitary equipment; - Never open the filler cap of the cooling circuit when the
engine is hot. Operating pressure would provoke hot
- Provide for adequate fire extinguishing means, properly liquid to pour out with serious danger and risk of
indicated and always easy to reach. Their efficiency must scalding. Wait until the temperature decreases below 50
be checked on a regular basis and the personnel must be C;
trained on intervention methods and priorities;
- Never top up an overheated engine with cooler and use
- Provide specific exit points to evacuate the areas in case only appropriate liquids;
of emergency, giving adequate indications of emergency
escape paths; - Always operate with the engine turned off: in case
particular circumstances require maintenance
- Smoking in working areas subject to fire danger must be intervention on the running engine, be aware of all risks
strictly prohibited; involved in such operation;
- Provide warnings by means of adequate boards signaling - Be equipped with adequate and safe containers for
danger, prohibitions, and indications to ensure easy draining engine liquids and exhaust oil;
understanding of the instructions even in case of
emergency. - Keep the engine clean from oil, diesel fuel, and/or
chemical solvents stains;
Accident prevention - The use of solvents or detergents during maintenance
- When working close to engines and equipment in may generate toxic vapors. Always keep working areas
motion, do not wear unsuitable clothes, with loose ends, ventilated. Whenever necessary wear a safety mask;
nor jewels such as rings and chains;
- Do not leave rags impregnated with flammable
- Wear safety gloves and goggles when performing the substances close to the engine;
following operations:
- Upon engine start after maintenance, undertake proper
- Filling inhibitors or antifreeze; preventive action to stop air suction in case of
- Topping or replacing lubrication oil; overspeed;
- Using compressed air or liquids under pressure - Do not use fast screwdriver tools;
(pressure allowed: 2 bar). - Never disconnect batteries when the engine is running;
- Wear a safety helmet when working close to hanging - Disconnect batteries before any intervention on the
loads or equipment operating at head height level; electrical system
- Always wear safety shoes and clothes that adhere to the - Disconnect batteries from the system to charge them
body, better if provided with elastics at the ends; with the battery charger;
- Use protection cream for your hands; - After every intervention, verify that the battery clips`
- Change wet clothes as soon as possible; polarity is correct and that the clips are tight and safe
from accidental short circuit and oxidation;
- In presence of current tension exceeding 48-60 V verify
the efficiency of earth and mass electrical connections. - Do not disconnect or connect electrical connections
Ensure that hands and feet are dry and carry out working while the power is connected.
operations using isolating foot-boards. Do not carry out
working operations you are not trained for;
- Do not smoke nor have exposed flames close to
batteries and flammable material;
C87 ENT M38.10
9.186 C87 ENT M62.10 SAFETY REGULATIONS OCTOBER 2010
- Before proceeding with pipeline disassembly Respecting the Environment

(pneumatic, hydraulic, fuel pipes) check for liquid or air - Respecting the Environment is of primary importance:
under pressure. Take all necessary precautions by all necessary precautions to ensure the personnel's
bleeding and draining residual pressure or closing safety and health must be adopted;
separation valves. Always wear adequate safety masks or
goggles. Nonobservance of these instructions may cause - Be informed and also inform the personnel of laws in
serious injuries and poisoning; force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate noticeboards and
- Avoid incorrect or over-torque tightening. Danger: organize specific training courses to ensure that
incorrect tightening may seriously damage the engine's personnel is fully aware of such legal obligations and of
components, affecting its lifetime; basic preventive safety measures;
- Avoid priming from fuel tanks made of copper alloys - Collect exhaust oils in adequate containers with air-tight
and/or with ducts without filters; sealing ensuring that storage is made in specific, properly
- Do not modify cable wires: their length must not be identified, areas that are ventilated, away from heat
changed; sources, and not exposed to fire danger;
- Do not connect any other equipment to the engine's - Handle batteries with care, storing them in a ventilated
electrical equipment unless specifically approved by FPT; environment and in anti-acid containers. Warning:
battery exhalations represent a serious danger of
- Do not modify the fuel or hydraulic systems without intoxication and environment contamination.
having received specific approval from FPT. Any
unauthorized modifications will compromise the
warranty assistance and furthermore may affect the
correct operation and lifetime of the engine.
For engines equipped with an electronic control unit:

- Do not carry out any electric arc welding without having
removed the electronic control unit first;
- Remove the electronic control unit in case of any
interventions requiring heating over 80 C;
- Do not paint the components and the electronic
connections;
- Do not vary or alter any data filed in the electronic
control unit. Any manipulation or alteration of electronic
components will fully compromise the engine's warranty
of assistance and furthermore may affect the correct
operation and lifetime of the engine.
FPT - Fiat Powertrain Technologies
www.fptpowertrain.com

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C87 ENT M38.

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9. SAFETY REGULATIONS . . . . . . . . . . . . . . . . 183

PAGE LEFT INTENTIONALLY BLANK

PRODUCT MODEL NUMBER . . . . . . . . . . . 9

COMBUSTION AIR INTAKE AND EXHAUST

Comburent air filter . . . . . . . . . . . . . . . . . . . . . 11

Air/sea-water heat exchanger . . . . . . . . . . . . . 11

COOLING FRESH WATER CLOSED LOOP 12

Tube bundle water/water heat exchanger . . . 13

Bypass junction for thermostatic valve . . . . . . 13

SEAWATER OPEN COOLING LOOP . . . . . 14

Sea water pump . . . . . . . . . . . . . . . . . . . . . . . 15

ENGINE OIL - LUBRICATION LOOP . . . . . . 16

Oil fume recycle (Blow-by) . . . . . . . . . . . . . . . 17

FUEL SUPPLY DIAGRAM . . . . . . . . . . . . . . . . 19

Low pressure feed pump . . . . . . . . . . . . . . . . . 21

Pressure control solenoid valve . . . . . . . . . . . . 23

Low pressure limiter valve . . . . . . . . . . . . . . . . 23

High pressure pump . . . . . . . . . . . . . . . . . . . . 24

RAIL (PRESSURE ACCUMULATOR) . . . . . . . 26

EDC 7 Electronic Central Unit . . . . . . . . . . . . 27

Air pressure/temperature sensor . . . . . . . . . . 27

Atmospheric pressure sensor . . . . . . . . . . . . . 27

Oil pressure/temperature sensor . . . . . . . . . . 28

Coolant temperature sensor . . . . . . . . . . . . . . 29

Fuel temperature sensor . . . . . . . . . . . . . . . . . 30

Throttle lever position . . . . . . . . . . . . . . . . . . 30

Fuel pressure sensor on rail . . . . . . . . . . . . . . 30

Metering and fuel injection . . . . . . . . . . . . . . . 31

Injection advance management . . . . . . . . . . . . 31

Injection pressure modulation . . . . . . . . . . . . . 32

EDC indicator light . . . . . . . . . . . . . . . . . . . . . 32

Linearization of the acceleration gradient . . . . 32

Balance of the cylinder torque delivery . . . . . . 32

Rotation speed control . . . . . . . . . . . . . . . . . . 32

Top speed limitation . . . . . . . . . . . . . . . . . . . . 32

1. Trade name/version - 2. Homologation - 3. Production serial number- 4. Maximum rated power -

MAXIMUM PERFORMANCE LEVEL ACHIEVABLE

AIR INTAKE: T = INTERCOOLED SUPERCHARGED

BLOCK: N = NON STRUCTURAL

FUEL SUPPLY: E = ELECTRONIC INJECTION

DISPLACEMENT: 8.710 c.c.

ENGINE FAMILY IDENTIFIER: C = CURSOR

PRODUCT MODEL NUMBER

ACTUAL POWER OUTPUT

INTENDED USE (6 = MARINE)

FUEL + INJECTION (8 = DIESEL, TCA, DIRECT INJECTION)

NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL)

ENGINE FAMILY IDENTIFIER

COMBUSTION AIR INTAKE AND EXHAUST SYSTEM

Intake Exhaust Sea water

Comburent air filter Air/sea-water heat exchanger

1. Filter clogging sensor.

1. Sea-water outlet - 2. Sacrificial anode (Zinc) -

COOLING FRESH WATER CLOSED LOOP

High temperature liquid

Description and operation

Tube bundle water/water heat exchanger

Bypass junction for thermostatic valve

SEA WATER OPEN COOLING LOOP

Sea water pump

1. Pump impeller seat - 2. Driving gear shaft -

ENGINE OIL - LUBRICATION LOOP